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Grove Crane GMK 5100LSA Operating Manual 3303106 – PDF DOWNLOAD
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Description
Grove Crane GMK 5100LSA Operating Manual 3303106 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5100LSA Operating Manual 3303106 – PDF DOWNLOAD
Language : English
Pages : 1048
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 5100LSA Operating Manual 3303106 – PDF DOWNLOAD
Documentation supplied:
The precise number of documents supplied depends on the rigging mode of the truck crane. The
following documents are included in delivery:
– Operating manual
Contains information on driving and crane operation.
Contains information on driving and crane operation.
– Lattice extension operating manual
Is only supplied when the truck crane is equipped with a lattice extension or other parts for
extending the main boom (for example, auxiliary single- sheave boom top and heavy load lattice
extension).
Is only supplied when the truck crane is equipped with a lattice extension or other parts for
extending the main boom (for example, auxiliary single- sheave boom top and heavy load lattice
extension).
– Operating manual for additional equipment
This is only supplied when the truck crane is supplied with additional equipment which is not
described in the operating manual for driving and crane operation.
This is only supplied when the truck crane is supplied with additional equipment which is not
described in the operating manual for driving and crane operation.
– Documents from other manufacturers
Original documentation for parts not manufactured by Manitowoc Crane Group Germany GmbH, such as
the engine and central lubrication system, as well as the tachograph, auxiliary heaters, radio and,
where appropri- ate, other additional equipment.
Original documentation for parts not manufactured by Manitowoc Crane Group Germany GmbH, such as
the engine and central lubrication system, as well as the tachograph, auxiliary heaters, radio and,
where appropri- ate, other additional equipment.
– Maintenance manual
Contains solely information on maintenance work and contains no instructions for repair work.
Contains solely information on maintenance work and contains no instructions for repair work.
– Safety manual
Provides information on the safe operation of the truck crane.
Provides information on the safe operation of the truck crane.
– Circuit diagrams
Circuit diagrams for the electrical systems, hydraulic systems and pneu- matic systems are
supplied.
Circuit diagrams for the electrical systems, hydraulic systems and pneu- matic systems are
supplied.
– Lifting capacity table
Information on the lifting capacity when the truck crane is in different
rigging modes.
Information on the lifting capacity when the truck crane is in different
rigging modes.
TABLE OF CONTENTS:
Grove Crane GMK 5100LSA Operating Manual 3303106 – PDF DOWNLOAD
Operating manual............................................................................................................. 1 Correction sheet......................................................................................................... 3 Hook blocks.......................................................................................................... 3 Additional pages......................................................................................................... 7 MAXbase.............................................................................................................. 7 Outrigger spans...................................................................................................... 9 Counterweight on the rear storage area............................................................................... 11 Driving from the crane cab........................................................................................... 13 Telescoping emergency programe....................................................................................... 15 Crane cab heating and air-conditioning system........................................................................ 17 Outrigger control units.............................................................................................. 19 Steering system warning.............................................................................................. 21 Table of contents........................................................................................................ 25 General.................................................................................................................. 55 1 Overview........................................................................................................... 55 1.1 Accidents.................................................................................................... 55 1.2 Branch offices............................................................................................... 57 1.2.1 Manitowoc Crane Care................................................................................... 57 1.2.2 Dealer list............................................................................................ 57 1.3 Warranty specifications...................................................................................... 57 1.4 Terms used................................................................................................... 58 1.5 Technical data............................................................................................... 61 1.5.1 Maximum lifting capacity (DIN/ ISO/ EN)................................................................ 61 1.5.2 Dimensions and weights of the truck crane, axle loads.................................................. 62 Dimensions............................................................................................... 63 Weight and axle loads.................................................................................... 63 1.5.3 Dimensions and weights of removable parts.............................................................. 64 Spare wheel.............................................................................................. 64 Outrigger................................................................................................ 64 Main boom................................................................................................ 64 Hook blocks and hook tackle.............................................................................. 65 Auxiliary hoist.......................................................................................... 67 Counterweight parts...................................................................................... 68 1.5.4 Carrier................................................................................................ 71 Engine................................................................................................... 71 Transmission............................................................................................. 71 Transfer case............................................................................................ 71 Axle lines............................................................................................... 71 Steering................................................................................................. 72 Tyres.................................................................................................... 72 Turning turning radii.................................................................................... 72 Outrigger................................................................................................ 73 Electrical system........................................................................................ 74 Tool..................................................................................................... 74 Towing couplings......................................................................................... 74 Driving speeds........................................................................................... 74 Climbing ability......................................................................................... 74 1.5.5 Superstructure......................................................................................... 75 Main hoist............................................................................................... 75 Auxiliary hoist.......................................................................................... 75 Slewing gears............................................................................................ 75 Derricking gear.......................................................................................... 75 Main boom................................................................................................ 76 Lattice extension........................................................................................ 76 Operating speeds......................................................................................... 76 1.6 Documentation supplied....................................................................................... 77 1.6.1 Questions on documentation............................................................................. 78 1.7 Notes on the operating manual................................................................................ 79 1.7.1 What do the symbols used mean?......................................................................... 79 1.7.2 How is the operating manual structured?................................................................ 81 Division................................................................................................. 81 Structure of the chapters................................................................................ 81 Structure of the pages................................................................................... 82 1.7.3 How do I find the information I need?.................................................................. 83 Cross-references example................................................................................. 84 1.7.4 What information is available for operations planning?................................................. 86 1.8 Conversion table for US measuring units...................................................................... 87 1.9 Training - Information....................................................................................... 89 1.10 Identification.............................................................................................. 90 1.11 EC Declaration of Conformity................................................................................ 92 2 Basic safety instructions.......................................................................................... 93 2.1 Intended use................................................................................................. 93 2.1.1 Improper use........................................................................................... 94 2.2 Organisational measures...................................................................................... 95 2.3 Personnel qualifications..................................................................................... 97 2.4 Safety instructions for driving the truck crane.............................................................. 98 2.5 Safety instructions for crane operation...................................................................... 99 2.6 Instructions on transporting persons......................................................................... 102 Equipment for lifting persons................................................................................ 102 Personnel.................................................................................................... 102 Operation.................................................................................................... 103 Truck crane.................................................................................................. 104 Driving.................................................................................................................. 105 3 Operating elements for driving..................................................................................... 105 3.1 Overview of the operating elements........................................................................... 105 3.1.1 On the outside of the truck crane...................................................................... 106 3.1.2 Driver's cab........................................................................................... 110 Front overview........................................................................................... 110 Rear overview............................................................................................ 112 Behind the cover......................................................................................... 113 3.1.3 Steering column/steering wheel......................................................................... 114 3.1.4 Instrument panel....................................................................................... 115 Left/right............................................................................................... 115 Middle................................................................................................... 116 3.1.5 Transmission operating elements........................................................................ 118 3.1.6 On-board computer...................................................................................... 119 3.1.7 Tachograph............................................................................................. 120 3.1.8 Heating and air-conditioning system.................................................................... 121 Standard................................................................................................. 121 Auxiliary water heating system........................................................................... 122 Auxiliary air heater..................................................................................... 123 3.1.9 CCS control unit....................................................................................... 125 3.1.10 CCS – menu-dependent displays......................................................................... 126 3.1.11 CCS – Start menu...................................................................................... 127 3.1.12 CCS – Overview menu groups............................................................................ 128 3.1.13 Carrier menu group.................................................................................... 130 Suspension/level adjustment menu......................................................................... 131 Driving menu............................................................................................. 132 3.1.14 Settings menu group................................................................................... 133 Set display brightness and date/time menu................................................................ 134 Switch units menu........................................................................................ 135 3.1.15 Menu group Information................................................................................ 136 Operating hours menu..................................................................................... 137 Engine/transmission error menu........................................................................... 138 Crane operation error menu............................................................................... 139 3.1.16 Various controls menu group........................................................................... 140 3.1.17 Emergency operations menu group....................................................................... 141 3.1.18 Outrigger control units............................................................................... 142 3.2 Short description of the operating elements.................................................................. 143 3.2.1 Definition of information relating to directions of movement........................................... 144 Basic rule............................................................................................... 144 3.2.2 General rules for buttons and symbols on the display................................................... 145 3.2.3 Engine................................................................................................. 146 Steering column.......................................................................................... 146 On the steering wheel.................................................................................... 146 Instrument panel......................................................................................... 147 3.2.4 AdBlue system.......................................................................................... 148 Instrument panel......................................................................................... 148 CCS display.............................................................................................. 149 3.2.5 Battery master switch.................................................................................. 149 3.2.6 Electrical system...................................................................................... 150 3.2.7 Crane control CCS...................................................................................... 151 3.2.8 Transmission........................................................................................... 153 Transmission control unit................................................................................ 153 Display, driving mode.................................................................................... 155 3.2.9 Reverse camera......................................................................................... 156 3.2.10 BirdView system 270°.................................................................................. 157 3.2.11 Transfer case......................................................................................... 159 3.2.12 Final drive........................................................................................... 161 3.2.13 Brakes................................................................................................ 162 Service brake............................................................................................ 162 Additional brakes........................................................................................ 162 Parking brake............................................................................................ 163 3.2.14 Steering/separate steering............................................................................ 164 Instrument panel......................................................................................... 164 CCS display.............................................................................................. 166 3.2.15 Suspension............................................................................................ 168 CCS display.............................................................................................. 168 3.2.16 Lighting/windscreen wipers/horn....................................................................... 169 Steering column.......................................................................................... 169 Steering wheel........................................................................................... 169 Instrument panel......................................................................................... 169 CCS display.............................................................................................. 171 Roof..................................................................................................... 171 3.2.17 Level adjustment system............................................................................... 172 3.2.18 Tachograph/speedometer................................................................................ 174 Tachograph............................................................................................... 174 Cover.................................................................................................... 174 Speedometer.............................................................................................. 174 3.2.19 Diagnostics........................................................................................... 175 3.2.20 Push-up roof.......................................................................................... 175 3.2.21 On-board computer..................................................................................... 176 3.2.22 Front flap............................................................................................ 177 3.2.23 Windows and doors..................................................................................... 178 Window winder............................................................................................ 178 Doors.................................................................................................... 179 3.2.24 Access ladders and ladders............................................................................ 181 4 Starting the engine for driving / switching it off................................................................. 185 4.1 Starting the engine from the driver's cab.................................................................... 185 4.1.1 CHECKLIST: Starting the engine......................................................................... 185 4.1.2 CHECKLIST: At low temperatures......................................................................... 188 4.1.3 Filling up............................................................................................. 189 Fuel tank................................................................................................ 189 AdBlue tank.............................................................................................. 191 4.1.4 Checks before starting the engine...................................................................... 192 At the hydraulic tank.................................................................................... 192 Battery master switch.................................................................................... 193 Checking the hand-held control........................................................................... 193 4.1.5 Switch the ignition on................................................................................. 193 4.1.6 Lamp test/equalisation of the switching states......................................................... 194 Lamp test................................................................................................ 194 Switching state alignment................................................................................ 194 4.1.7 Display – setting the brightness....................................................................... 195 4.1.8 Starting the engine.................................................................................... 197 4.1.9 Checks after starting the engine....................................................................... 199 Start menu and on-board computer......................................................................... 199 Instrument panel......................................................................................... 200 4.1.10 Setting the idling speed.............................................................................. 201 4.2 Switch off the engine........................................................................................ 202 4.2.1 At the ignition lock and with the outrigger control units.............................................. 202 After switching off...................................................................................... 202 4.2.2 Using the emergency stop switches...................................................................... 203 Resetting the emergency stop switch...................................................................... 203 4.3 Air intake inhibitor......................................................................................... 204 Opening the air intake inhibitor............................................................................. 204 5 Driving............................................................................................................ 205 5.1 Before driving............................................................................................... 205 5.1.1 CHECKLIST: checks before on-road driving............................................................... 205 5.1.2 Check the condition of the truck crane................................................................. 211 Electrical system........................................................................................ 211 Adjusting the mirrors.................................................................................... 211 Warning plates for vehicle width......................................................................... 213 Checking the vehicle height.............................................................................. 213 Supply pressure.......................................................................................... 214 Parking brake............................................................................................ 215 Third brake light........................................................................................ 216 5.1.3 Adjusting the seat and the steering column............................................................. 217 Adjusting the driver's seat.............................................................................. 217 Adjusting the passenger seat............................................................................. 218 Adjusting the steering column............................................................................ 219 5.1.4 Switching the suspension on/off........................................................................ 220 Open menu................................................................................................ 220 Switching the suspension on.............................................................................. 221 Switching the suspension off............................................................................. 221 5.1.5 Setting the tachograph................................................................................. 222 Prerequisites............................................................................................ 222 In the event of malfunctions............................................................................. 222 Setting the tachograph................................................................................... 223 5.1.6 Setting the time....................................................................................... 227 5.1.7 Displaying and resetting operating hours............................................................... 228 5.2 Operating the transmission................................................................................... 229 5.2.1 Switching on........................................................................................... 229 5.2.2 Switching the transmission to the neutral position..................................................... 230 5.2.3 Selecting the direction of travel and starting gear.................................................... 231 Selecting the driving direction.......................................................................... 231 Selecting the starting gear.............................................................................. 232 5.2.4 Changing the operating mode............................................................................ 233 Changing to automatic mode............................................................................... 233 Change to manual mode.................................................................................... 233 5.2.5 Starting............................................................................................... 234 5.2.6 Driving and changing gears............................................................................. 235 In automatic operating mode.............................................................................. 235 In manual operating mode................................................................................. 236 5.2.7 Changing the driving direction......................................................................... 237 5.2.8 Stopping............................................................................................... 237 Stopping for longer periods.............................................................................. 237 5.2.9 On the roller type dynamometer......................................................................... 238 5.2.10 Preheating transmission............................................................................... 238 5.3 Driving the truck crane and switching it off................................................................. 239 5.3.1 Checks whilst driving.................................................................................. 239 Brakes................................................................................................... 239 ABS system............................................................................................... 239 Steering................................................................................................. 240 Warning messages......................................................................................... 240 Monitoring elements...................................................................................... 241 5.3.2 Cruise control......................................................................................... 242 Switching on............................................................................................. 242 Switching off............................................................................................ 243 5.3.3 Temposet............................................................................................... 244 Switching on............................................................................................. 244 Switching off............................................................................................ 244 5.3.4 Driving downhill....................................................................................... 245 Starting................................................................................................. 245 Checks when driving downhill............................................................................. 246 Downshifting............................................................................................. 246 Additional brakes........................................................................................ 247 5.3.5 Driving uphill......................................................................................... 248 Starting................................................................................................. 248 Driving.................................................................................................. 248 5.3.6 Overriding torque reduction............................................................................ 249 5.3.7 Switching the truck crane off.......................................................................... 250 Secure it against rolling away........................................................................... 250 When stationary for more than 8 hours.................................................................... 251 5.3.8 Fold-up berth.......................................................................................... 252 5.4 Off-road driving............................................................................................. 253 Adjustments to the transmission.............................................................................. 253 Connections.................................................................................................. 253 Changing the vehicle level................................................................................... 253 Rocking the vehicle free and towing.......................................................................... 253 5.4.1 Transfer case – switching the off-road gear on/off..................................................... 254 5.4.2 Longitudinal and transverse differential locks......................................................... 255 5.4.3 Operating the level adjustment system.................................................................. 257 Open menu................................................................................................ 257 Setting the on-road level................................................................................ 258 Pre-selecting suspension struts.......................................................................... 258 Changing the vehicle level............................................................................... 259 Viewing the current inclination.......................................................................... 260 Exiting the menu......................................................................................... 260 5.4.4 Freeing truck crane stuck in terrain................................................................... 261 Rocking the truck crane free............................................................................. 261 Towing free forwards..................................................................................... 262 Towing free to the rear.................................................................................. 262 5.5 Separate steering............................................................................................ 263 5.5.1 Switching to separate steering......................................................................... 264 5.5.2 Switching to normal steering mode...................................................................... 267 5.5.3 Switching units of measure............................................................................. 268 5.6 Heating and air-conditioning system.......................................................................... 269 5.6.1 Standard heating system................................................................................ 269 Switching on............................................................................................. 269 Heating.................................................................................................. 269 Air distribution......................................................................................... 270 Examples................................................................................................. 271 Switching off............................................................................................ 271 5.6.2 Air-conditioning system................................................................................ 272 Notes.................................................................................................... 272 Switching on/off......................................................................................... 272 Cooling.................................................................................................. 273 Drying................................................................................................... 273 5.6.3 Auxiliary water heating system......................................................................... 274 Preheating the engine.................................................................................... 274 Preheating the driver's cab.............................................................................. 275 Switching on............................................................................................. 275 Setting the date and time................................................................................ 277 Storing the heating start................................................................................ 278 5.6.4 Auxiliary air heater................................................................................... 280 Switching on............................................................................................. 280 Setting the heating level................................................................................ 281 Setting the day and time................................................................................. 282 Setting the preselection time............................................................................ 282 Preselection times Delete................................................................................ 284 Switching off............................................................................................ 284 5.7 Radio........................................................................................................ 284 5.8 Towing a trailer............................................................................................. 285 Effects on the axle loads.................................................................................... 285 Coupling the trailer......................................................................................... 286 Connecting the supply lines.................................................................................. 287 Removing supply lines........................................................................................ 288 Uncoupling the trailer....................................................................................... 288 Checking the braking force................................................................................... 290 6 Driving modes and rigging for on-road driving...................................................................... 291 6.1 Driving modes................................................................................................ 291 Information about the axle loads............................................................................. 291 6.1.1 How to use the tables.................................................................................. 292 6.1.2 Table for a maximum axle load of 12 t.................................................................. 293 Tyres 385/95 R25......................................................................................... 293 Tyres 445/95 R25......................................................................................... 294 Tyres 525/80 R25......................................................................................... 295 6.1.3 Maximum permitted speeds with an axle load of over 12 t................................................ 296 6.2 Weighing the truck crane..................................................................................... 297 Axle groups.................................................................................................. 298 Weighing procedure........................................................................................... 299 Evaluation................................................................................................... 300 6.3 Rigging work for driving with a dolly........................................................................ 301 6.3.1 Switching on the slewing gear freewheel................................................................ 302 6.3.2 Switching on the boom floating position................................................................ 303 6.3.3 Switching on boom pre-tensioning....................................................................... 304 6.3.4 Raising/lowering the 3rd axle line for dolly operation................................................. 305 6.4 Rigging the main boom........................................................................................ 307 Additional equipment required................................................................................ 307 6.4.1 CHECKLIST: Removing the main boom...................................................................... 308 Prerequisites............................................................................................ 308 Checklist................................................................................................ 308 6.4.2 CHECKLIST: Mounting the main boom...................................................................... 311 Prerequisites............................................................................................ 311 Checklist................................................................................................ 311 6.4.3 Disconnecting/connecting hydraulics/electrical......................................................... 314 6.4.4 Derricking cylinder support............................................................................ 316 6.4.5 Slinging the main boom................................................................................. 316 Marking.................................................................................................. 316 Attach lifting gear...................................................................................... 317 Removing the sling gear.................................................................................. 318 6.4.6 Switching the pressure relief on/off................................................................... 319 6.4.7 Retracting/fitting the derricking cylinder head pin.................................................... 320 Operating the lifting device............................................................................. 320 Pulling the derricking cylinder head axle................................................................ 320 Fitting the derricking cylinder head axle................................................................ 321 6.4.8 Extending/retracting the boom pivot pin................................................................ 322 Pulling out the pivot pin................................................................................ 322 Pushing the pivot pin in................................................................................. 324 6.4.9 Transporting the main boom............................................................................. 325 6.4.10 Securing/releasing the derricking cylinder............................................................ 325 6.4.11 Aligning the connecting points........................................................................ 326 6.4.12 Inspections after main boom mounting.................................................................. 327 6.5 Rigging the auxiliary hoist.................................................................................. 329 6.5.1 Slinging the auxiliary hoist........................................................................... 329 6.5.2 CHECKLIST: Installing the auxiliary hoist.............................................................. 330 6.5.3 CHECKLIST: Removing the auxiliary hoist................................................................ 331 6.5.4 Making/breaking the connection between the auxiliary hoist and the turntable........................... 332 6.5.5 Establishing/disconnecting the hydraulic connections................................................... 333 6.5.6 Disconnecting/establishing the electrical connection................................................... 334 6.5.7 Making/breaking the connection to the central lubrication.............................................. 335 6.5.8 Transporting the auxiliary hoist....................................................................... 336 6.5.9 Check that the auxiliary hoist is functioning properly................................................. 337 Slewing direction........................................................................................ 337 Slewing indicator........................................................................................ 337 6.5.10 Rigging aid for the hoist rope........................................................................ 338 6.6 Installing/removing the outrigger beams...................................................................... 341 6.6.1 CHECKLIST: Removing the outrigger beams................................................................ 342 6.6.2 CHECKLIST: Installing the outrigger beams.............................................................. 344 6.6.3 Centre of gravity data................................................................................. 346 6.6.4 Preparations – for removal............................................................................. 346 6.6.5 Preparations – on the truck crane...................................................................... 347 Prerequisites............................................................................................ 347 6.6.6 Removing/attaching outrigger pads...................................................................... 348 Removing the outrigger pads.............................................................................. 348 Attaching the outrigger pads............................................................................. 349 6.6.7 Disconnecting/establishing hydraulic connection........................................................ 350 6.6.8 Disconnecting/establishing the electrical connection................................................... 351 6.6.9 Unscrewing/screwing in the spacers..................................................................... 352 Unscrewing............................................................................................... 352 Screwing in.............................................................................................. 353 6.6.10 Disconnecting/establishing the connections to the supporting box...................................... 354 6.6.11 Pulling out/Inserting the outrigger beam.............................................................. 354 Extending the outrigger beam............................................................................. 354 Inserting the outrigger beam............................................................................. 356 6.6.12 Transporting the outrigger beams...................................................................... 358 6.6.13 Note on error messages with removed outrigger beams................................................... 358 7 Transport.......................................................................................................... 359 7.1 Transport with transport vehicle............................................................................. 359 7.1.1 CHECKLIST: Checks before transport..................................................................... 360 7.1.2 Drive the truck crane on to the transport vehicle...................................................... 362 Driving on............................................................................................... 363 Lashing.................................................................................................. 363 7.2 Transport by ship............................................................................................ 364 8 Malfunctions in driving mode....................................................................................... 365 8.1 Emergency stop switch........................................................................................ 365 8.2 Procedure during malfunctions................................................................................ 366 8.2.1 What to do when a malfunction occurs in road traffic................................................... 366 8.2.2 Procedure during engine malfunctions................................................................... 367 8.2.3 Procedure during transmission malfunctions............................................................. 368 8.3 Warning and error messages................................................................................... 369 8.3.1 Warning or malfunction messages on the instrument panel................................................ 369 Meaning of the lamps..................................................................................... 369 8.3.2 Warning and malfunction messages on the on-board computer display...................................... 373 Messages................................................................................................. 373 Symbols.................................................................................................. 374 8.3.3 Warning messages on the CCS display.................................................................... 377 Symbols in the display area.............................................................................. 377 8.3.4 Error messages on the CCS display...................................................................... 381 Exiting the menu......................................................................................... 382 Special error messages................................................................................... 382 8.4 Troubleshooting.............................................................................................. 383 8.4.1 Malfunctions on the engine............................................................................. 383 When operating with the dual tank........................................................................ 385 8.4.2 Faults on the Adblue system............................................................................ 385 8.4.3 Differential lock malfunctions......................................................................... 386 8.4.4 Transfer case malfunctions............................................................................. 386 8.4.5 Malfunctions in the transmission....................................................................... 387 8.4.6 Malfunctions of the steering........................................................................... 388 8.4.7 Malfunctions of the service brake...................................................................... 389 8.4.9 Malfunctions of the level adjustment system............................................................ 390 8.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler............................................. 390 8.5 Emergency operation and breakdown assistance................................................................. 391 8.5.1 Starting the truck crane externally.................................................................... 391 8.5.2 Battery charger........................................................................................ 392 Prerequisites............................................................................................ 392 8.5.3 Towing the truck crane................................................................................. 393 In the case of engine/transmission damage................................................................ 393 Longer towing distances.................................................................................. 396 Tow starting............................................................................................. 396 8.5.4 Wheel change........................................................................................... 397 Removing a damaged wheel................................................................................. 398 On the spare wheel holder................................................................................ 398 Mounting a wheel......................................................................................... 400 8.5.5 Inflating the tyres yourself........................................................................... 401 Connecting the filling hose.............................................................................. 401 Inflating the tyres...................................................................................... 402 Remove the filling hose.................................................................................. 402 8.5.6 Emergency operation, steering 3rd and 4th axle lines................................................... 403 Performing emergency operation........................................................................... 404 After emergency operation................................................................................ 406 8.6 Tilting/lowering the driver's cab............................................................................ 407 8.6.1 Prerequisites and information on tilting............................................................... 407 8.6.2 Tilting and lowering the driver's cab.................................................................. 408 Operating the hand pump.................................................................................. 408 Tilting the driver's cab................................................................................. 409 Lowering the driver's cab................................................................................ 410 8.7 Fuses on the carrier......................................................................................... 413 Information on changing fuses................................................................................ 413 8.7.1 Fuses in the driver's cab.............................................................................. 414 8.7.2 Fuses in the battery box............................................................................... 420 Crane operation.......................................................................................................... 105 9 Operating elements for crane operation............................................................................. 421 9.1 Overview of the operating elements........................................................................... 421 9.1.1 Exterior of the truck crane............................................................................ 422 9.1.2 Crane cab.............................................................................................. 426 Side panel............................................................................................... 428 Crane cab, rear.......................................................................................... 430 9.1.3 Control panels......................................................................................... 432 Left..................................................................................................... 432 Right.................................................................................................... 433 9.1.4 Control lever assignment............................................................................... 434 Version 1................................................................................................ 434 Version 2................................................................................................ 435 9.1.5 CCS control unit....................................................................................... 436 9.1.6 Menu-independent displays.............................................................................. 438 9.1.7 CCS – Start menu....................................................................................... 439 RCL display.............................................................................................. 440 Display Slewing ranges/working radii..................................................................... 441 9.1.8 CCS – Overview menu groups............................................................................. 442 9.1.9 Superstructure menu group.............................................................................. 446 Superstructure lock sub-menu............................................................................. 447 Counterweight menu....................................................................................... 448 9.1.10 Menu group outrigger/driving.......................................................................... 449 Outrigger menu........................................................................................... 450 Outrigger cylinders menu................................................................................. 452 Driving menu............................................................................................. 454 9.1.11 RCL/Telescoping menu group............................................................................ 457 Menu enter rigging mode/ telescope....................................................................... 458 Pre-selection telescoping menu........................................................................... 462 Lifting capacity tables menu............................................................................. 464 Telescoping semi- automation menu........................................................................ 465 Manual telescoping menu.................................................................................. 466 9.1.12 Working range limiter menu group...................................................................... 467 Overall height menu...................................................................................... 468 Working radius menu...................................................................................... 469 Slewing angle menu....................................................................................... 470 Hoist rope travel limitation menu........................................................................ 471 9.1.13 Information 1 menu group.............................................................................. 472 Hydraulic pressure and fuel consumption menu............................................................. 473 9.1.14 Heating/Engine/Additional equipment menu group........................................................ 474 Economy menu............................................................................................. 475 Remote control menu...................................................................................... 476 Heating/air- conditioning menu........................................................................... 477 Spotlights menu.......................................................................................... 478 9.1.15 Telescoping emergency program menu group.............................................................. 479 Telescoping emergency program menu....................................................................... 480 Unknown telescoping menu................................................................................. 482 9.1.16 Menu group, settings.................................................................................. 483 Crane cab menu........................................................................................... 484 Set display brightness and date/time menu................................................................ 485 Switch units menu........................................................................................ 486 Set control lever characteristic curve menu.............................................................. 487 Power unit speeds menu................................................................................... 488 9.1.17 Information 2 menu group.............................................................................. 489 Operating hours menu..................................................................................... 490 Engine/ transmission error menu.......................................................................... 491 Crane operation error menu............................................................................... 492 Program version menu..................................................................................... 493 9.1.18 Various controls...................................................................................... 495 9.1.19 RCL control unit...................................................................................... 496 9.1.20 Menu-independent displays............................................................................. 497 9.1.21 RCL – menus........................................................................................... 498 Monitoring menu.......................................................................................... 498 Lifting capacity tables menu............................................................................. 500 Datalogger menu.......................................................................................... 501 9.1.22 Hand-held control..................................................................................... 503 9.1.23 Outriggers control units.............................................................................. 505 Menu- independent buttons................................................................................ 505 Outrigger menu........................................................................................... 506 Raise axle menu.......................................................................................... 508 9.2 Short description of the operating elements.................................................................. 509 9.2.1 Definition of information relating to directions of movement........................................... 509 Basic rule............................................................................................... 509 9.2.2 General rules for buttons and symbols on the display................................................... 510 9.2.3 Engine................................................................................................. 511 Side panel............................................................................................... 511 Left control lever....................................................................................... 511 Economy mode menu........................................................................................ 512 9.2.4 AdBlue system.......................................................................................... 512 CCS display.............................................................................................. 512 9.2.5 Seat contact switch and dead man's switch.............................................................. 514 9.2.6 Crane control CCS...................................................................................... 515 9.2.7 Outrigger – crane cab.................................................................................. 520 Control panels........................................................................................... 520 CCS display.............................................................................................. 521 9.2.8 Outrigger control units................................................................................ 523 General information...................................................................................... 523 Outrigger menu........................................................................................... 524 9.2.9 Raise axle............................................................................................. 526 9.2.10 Inclination indicators................................................................................ 528 9.2.11 Outrigger pressure displays........................................................................... 529 Outrigger menu........................................................................................... 529 Outriggers control units................................................................................. 529 9.2.12 Anemometer displays................................................................................... 529 9.2.13 Counterweight menu.................................................................................... 530 9.2.14 Main hoist............................................................................................ 534 Control panels........................................................................................... 534 CCS display.............................................................................................. 534 9.2.15 Auxiliary hoist....................................................................................... 536 Control panels........................................................................................... 536 CCS display.............................................................................................. 537 9.2.16 Slewing gear.......................................................................................... 538 Control panels........................................................................................... 538 CCS display.............................................................................................. 539 9.2.17 Derricking gear....................................................................................... 540 Control panels........................................................................................... 540 CCS display.............................................................................................. 541 Side panel............................................................................................... 541 9.2.18 Telescoping mechanism................................................................................. 542 Control panels........................................................................................... 542 CCS display.............................................................................................. 543 Telescoping semi- automation menu........................................................................ 543 Manual telescoping menu.................................................................................. 545 9.2.19 Hydraulic system...................................................................................... 548 9.2.20 Superstructure lock/house lock menu................................................................... 549 Superstructure lock...................................................................................... 549 Houselock................................................................................................ 551 9.2.21 Remote control........................................................................................ 552 9.2.22 Rated capacity limiter (RCL).......................................................................... 553 CCS display.............................................................................................. 553 RCL display.............................................................................................. 562 RCL override – version A................................................................................. 563 RCL override – version B................................................................................. 564 9.2.23 Electrical system..................................................................................... 565 9.2.24 Lighting, windscreen wiper/washing system............................................................. 566 Lighting................................................................................................. 566 Windscreen wiper/washing system.......................................................................... 568 Horn..................................................................................................... 569 9.2.25 Hand-held control..................................................................................... 570 Sockets for hand- held control........................................................................... 570 Engine control panel..................................................................................... 571 Horn..................................................................................................... 571 9.2.26 Windows and doors..................................................................................... 574 window................................................................................................... 574 rear window.............................................................................................. 574 Crane cab door........................................................................................... 575 9.2.27 Diagnostics........................................................................................... 576 9.2.28 Other................................................................................................. 576 9.3 Short description of the operating elements – driving from the crane cab..................................... 577 9.3.1 Driving menu........................................................................................... 577 9.3.2 Transmission........................................................................................... 579 9.3.3 Final drive............................................................................................ 581 9.3.4 Brakes................................................................................................. 582 CCS display.............................................................................................. 582 Side panel from above.................................................................................... 582 9.3.5 Steering............................................................................................... 583 CCS display.............................................................................................. 584 Control panels........................................................................................... 586 10 Starting/switching off the engine – for crane operation........................................................... 587 10.1 When starting the engine for the first time in the day...................................................... 587 10.2 Starting the engine – from the crane cab.................................................................... 589 10.2.1 Check the fuel level and AdBlue level................................................................. 589 Fuel..................................................................................................... 589 AdBlue................................................................................................... 589 10.2.2 Checks before starting the engine..................................................................... 590 Checks on the carrier.................................................................................... 590 Checking the hand-held control........................................................................... 590 At the hydraulic tank.................................................................................... 590 10.2.3 Switching the ignition on............................................................................. 591 10.2.4 Comparison of switching states........................................................................ 592 10.2.5 Display – setting the brightness...................................................................... 592 10.2.6 Starting the engine................................................................................... 593 10.2.7 Checks after starting the engine...................................................................... 594 10.2.8 Setting the idling speed.............................................................................. 595 10.3 Starting the engine – with the hand-held control............................................................ 596 10.4 Switch off the engine....................................................................................... 597 10.4.1 At the ignition lock and with hand-held control....................................................... 597 After switching off...................................................................................... 597 10.4.2 With the idling button................................................................................ 597 10.4.3 Using the emergency stop switches..................................................................... 598 Emergency stop switch, resetting......................................................................... 598 11 Crane operation................................................................................................... 599 11.1 Before operating the crane.................................................................................. 599 11.1.1 CHECKLIST: Checks before operating the crane.......................................................... 599 11.1.2 Check the condition of the truck crane................................................................ 603 Fuel tank auxiliary heater............................................................................... 603 Visual inspection........................................................................................ 603 Checking the position of the hoist ropes................................................................. 604 Checking the electrical system........................................................................... 605 11.1.3 Adjusting the crane cab seat and front control panel.................................................. 606 Crane cab seat........................................................................................... 606 Front control panel...................................................................................... 607 11.1.4 Checking the safety equipment......................................................................... 608 Rated capacity limiter................................................................................... 608 Lifting limit switch..................................................................................... 608 Emergency stop switch.................................................................................... 609 Seat contact switch...................................................................................... 610 11.1.5 Earthing the load..................................................................................... 611 11.1.6 Preheating hydraulic oil.............................................................................. 612 Prerequisites............................................................................................ 612 Preheating............................................................................................... 612 11.1.7 Locking/unlocking the superstructure.................................................................. 613 Locking points........................................................................................... 613 Lock the superstructure.................................................................................. 614 Unlocking the superstructure............................................................................. 614 11.1.8 Switching the houselock on/off........................................................................ 615 Switching on the houselock............................................................................... 615 Switching off the houselock.............................................................................. 617 11.2 Standard slewing range type................................................................................. 619 11.2.1 Permissible slewing ranges and working positions...................................................... 619 360° slewing range....................................................................................... 619 Working position 0° to the rear.......................................................................... 619 180° to the front rigging position....................................................................... 619 11.3 MAXbase slewing range type.................................................................................. 621 11.3.1 Specifications in the lifting capacity tables......................................................... 622 11.3.2 Enabled slewing ranges................................................................................ 623 11.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables.... 626 11.4 Operation of the rated capacity limiter..................................................................... 627 11.4.1 Switch on the RCL..................................................................................... 628 Switching on............................................................................................. 628 11.4.2 Enter rigging mode.................................................................................... 630 Notes on Input........................................................................................... 630 Enter the slewing range type............................................................................. 631 Entering individual components........................................................................... 632 Entering the RCL code.................................................................................... 638 11.4.3 Pre-selecting telescoping............................................................................. 638 11.4.4 Confirm the rigging mode and lifting capacity table................................................... 639 Slewing range type Standard.............................................................................. 639 Slewing range type MAXbase............................................................................... 641 11.4.5 Checks before operating the crane..................................................................... 643 Monitoring menu.......................................................................................... 643 Checking the rigging mode................................................................................ 643 Hoist checking........................................................................................... 645 11.4.6 Display during the crane operation.................................................................... 647 On the RCL display....................................................................................... 647 On the CCSdisplay........................................................................................ 651 11.4.7 RCL early warning..................................................................................... 655 11.4.8 RCL shutdown.......................................................................................... 655 Shutdown due to overload................................................................................. 655 11.4.9 Displaying the lifting capacity tables................................................................ 657 Slewing range type Standard.............................................................................. 657 Slewing range type MAXbase............................................................................... 659 11.4.10 RCL override – version A............................................................................. 661 Overview status display.................................................................................. 661 When rigging............................................................................................. 662 To raise the boom........................................................................................ 663 In emergencies........................................................................................... 664 11.4.11 RCL override – version B............................................................................. 665 11.4.12 Datalogger........................................................................................... 666 Export data.............................................................................................. 666 Display the data......................................................................................... 667 11.5 Crane operation with main boom.............................................................................. 671 11.5.1 Checks during crane operation......................................................................... 671 Horizontal alignment..................................................................................... 671 Safe distances........................................................................................... 671 Checking the wind speed.................................................................................. 672 11.5.2 Main hoist............................................................................................ 673 Switching on the main hoist.............................................................................. 674 Lifting and lowering..................................................................................... 675 Maximum permissible hoist rope speed..................................................................... 676 Switching off the main hoist............................................................................. 676 11.5.3 Auxiliary hoist....................................................................................... 677 Switching on the auxiliary hoist......................................................................... 677 Lifting and lowering..................................................................................... 678 Maximum permissible hoist rope speed..................................................................... 679 Switching off the auxiliary hoist........................................................................ 679 11.5.4 Lifting limit switch and lowering limit switch........................................................ 680 Lifting limit switch..................................................................................... 680 Lowering limit switch.................................................................................... 682 11.5.5 Derricking gear....................................................................................... 683 Switching on the derricking gear......................................................................... 683 Raising and lowering..................................................................................... 684 Maximum derricking speed................................................................................. 685 Re-enable raising function............................................................................... 685 Switching off the derricking gear........................................................................ 686 Lowering the main boom to a horizontal position.......................................................... 686 11.5.6 Telescoping mechanism................................................................................. 687 Overview................................................................................................. 689 Telescoping process...................................................................................... 690 Assignment for display................................................................................... 692 Fixed length, intermediate length, telescoping length.................................................... 693 Telescoping.............................................................................................. 694 Telescoping sequence..................................................................................... 694 Inspections prior to starting operations................................................................. 695 Switching on the telescoping mechanism................................................................... 696 Function of the control lever............................................................................ 696 Switching off the telescoping mechanism.................................................................. 698 Manual telescoping....................................................................................... 699 Checking the initial position,........................................................................... 699 Unlocking the telescoping cylinder....................................................................... 701 Extending/retracting the telescoping cylinder............................................................ 703 Lock telescoping cylinder................................................................................ 704 Unlocking the telescopic section......................................................................... 705 Telescoping the telescopic section....................................................................... 706 Locking the telescopic section........................................................................... 707 Locking the telescopic section for on-road driving....................................................... 708 Telescoping with semi-automaton.......................................................................... 708 Telescoping with pre-selection........................................................................... 710 11.5.7 High-speed mode....................................................................................... 711 Derricking gear Telescoping mechanism.................................................................... 711 Hoists................................................................................................... 711 11.5.8 Slewing gear.......................................................................................... 713 Slewing gear brake....................................................................................... 713 Switching on the slewing gear............................................................................ 714 Releasing the slewing gear brake......................................................................... 714 Applying the slewing gear brake.......................................................................... 714 Slewing.................................................................................................. 715 Permissible slewing speed................................................................................ 716 Braking the slewing movement............................................................................. 717 Slewing gear freewheel................................................................................... 717 Switching off the slewing gear........................................................................... 718 11.5.9 Switching the reduction of slewing speed on and off................................................... 719 Switching reduction off.................................................................................. 719 11.5.10 Possible movement combinations....................................................................... 720 11.6 Settings and displays for crane operation................................................................... 721 11.6.1 Inclining the crane cab............................................................................... 721 11.6.2 Idling speed, setting................................................................................. 722 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper........................................... 722 11.6.4 Limiting the power unit speeds........................................................................ 723 11.6.5 Economy mode.......................................................................................... 724 Switching on............................................................................................. 724 Ending/ switching off.................................................................................... 726 11.6.6 Switching units of measure............................................................................ 726 11.6.7 Setting the characteristic curves for the control levers.............................................. 727 11.6.8 Using the slewable spotlights......................................................................... 728 Manually swinging........................................................................................ 729 Automatic load tracking.................................................................................. 729 11.6.9 Overriding torque reduction........................................................................... 730 11.6.10 Displaying the operating hours....................................................................... 731 11.7 Working range limiter....................................................................................... 733 11.7.1 viewing current settings.............................................................................. 734 On the RCL dislay........................................................................................ 734 In the CCS Start menu.................................................................................... 735 11.7.2 Opening the working range limiter menu................................................................ 735 11.7.3 Enter limit values – for the overall height........................................................... 736 11.7.4 Enter limit values – for the working radius........................................................... 738 11.7.5 Enter limit values – for the slewing range............................................................ 740 11.7.6 Enter limit values – for the hoist rope travel........................................................ 743 11.7.7 Shutdown by working range limiter..................................................................... 745 11.8 Work break.................................................................................................. 747 11.8.1 In case of short work breaks.......................................................................... 747 11.8.2 In case of work breaks of more than 8 hours........................................................... 748 To secure the truck crane................................................................................ 748 11.9 Heating and air-conditioning system......................................................................... 749 11.9.1 Standard heating system............................................................................... 749 Switching on............................................................................................. 749 Heating.................................................................................................. 749 Air distribution......................................................................................... 750 Switching off............................................................................................ 750 11.9.2 Air-conditioning system............................................................................... 751 Notes.................................................................................................... 751 Switching on/off......................................................................................... 751 Cooling, automatic....................................................................................... 752 Cooling, maximum......................................................................................... 752 11.9.3 Auxiliary heater...................................................................................... 753 Switching on............................................................................................. 753 Setting the temperature.................................................................................. 754 Setting the heating start/ heating duration.............................................................. 754 Switching heating start on/off........................................................................... 755 11.10 CraneSTAR system........................................................................................... 756 11.10.1 Overview............................................................................................. 756 11.10.2 Position of the components........................................................................... 756 12 Rigging work...................................................................................................... 757 12.1 Rigging work checklists for crane operation with the main boom.............................................. 757 12.1.1 CHECKLIST: Rigging.................................................................................... 757 12.1.2 CHECKLIST: Unrigging.................................................................................. 763 12.2 Choice of a suitable positioning site....................................................................... 767 12.2.1 Determining the required load-bearing area............................................................ 767 12.2.2 Safe distance from slopes and pits.................................................................... 770 12.2.3 Earthing the truck crane.............................................................................. 771 12.2.4 Safe distance from overhead power lines............................................................... 772 12.3 Rigging work after driving with a dolly..................................................................... 775 12.3.1 Switching off the boom floating position.............................................................. 775 12.3.2 Switching off the slewing gear freewheel.............................................................. 776 Before slewing........................................................................................... 776 12.3.3 Switching off boom pre-tensioning..................................................................... 777 12.4 Connecting/disconnecting the hand-held control.............................................................. 779 12.5 Starting the engine for rigging............................................................................. 783 12.5.1 Starting/shutoff the engine – with the hand-held control.............................................. 783 Prerequisites............................................................................................ 783 Starting the engine...................................................................................... 784 Turning off the engine................................................................................... 784 12.5.2 Starting/shutoff the engine – from the outrigger control units........................................ 785 Prerequisites............................................................................................ 785 Starting the engine...................................................................................... 785 Switch off the engine.................................................................................... 785 12.6 Slewing range – only with the Standard slewing range type................................................... 787 12.6.1 Representation in the lifting capacity tables......................................................... 787 12.6.2 Enabled outrigger spans............................................................................... 788 12.7 Outriggers – Overview – MAXbase slewing range type.......................................................... 789 12.7.1 Definitions........................................................................................... 789 12.7.2 Representation in the lifting capacity tables......................................................... 791 12.7.3 Enabled outrigger spans............................................................................... 792 12.8 Outrigger operation......................................................................................... 797 12.8.1 CHECKLIST: Extending the outriggers................................................................... 797 12.8.2 CHECKLIST: Retracting the outriggers.................................................................. 799 12.8.3 Preparing the truck crane............................................................................. 800 Driver's cab............................................................................................. 800 Crane cab................................................................................................ 800 12.8.4 Setting the outrigger spans........................................................................... 802 For on-road driving...................................................................................... 805 12.8.5 Extending/retracting outrigger beams.................................................................. 805 From the crane cab....................................................................................... 806 From the control units................................................................................... 807 12.8.6 Moving the outrigger pads into operating/driving position............................................. 809 12.8.7 Enlarging the load-bearing area....................................................................... 811 12.8.8 Extending/retracting supporting cylinders............................................................. 812 From the control units................................................................................... 813 From the crane cab....................................................................................... 814 12.8.9 Levelling the truck crane on outriggers horizontally.................................................. 816 Inclination indicators................................................................................... 816 Prerequisites............................................................................................ 817 Manual alignment......................................................................................... 818 Automatic alignment...................................................................................... 818 12.8.10 Levelling the free-standing truck crane.............................................................. 820 12.8.11 Operating the axle raising system.................................................................... 822 12.8.12 Outrigger pressure display........................................................................... 824 12.9 Rigging/unrigging the counterweight......................................................................... 827 12.9.1 Information on rigging................................................................................ 827 When rigging............................................................................................. 827 When unrigging........................................................................................... 828 12.9.2 Counterweight sections................................................................................ 829 Version 1................................................................................................ 829 Version 2................................................................................................ 829 Version 3................................................................................................ 830 12.9.3 Identification........................................................................................ 831 12.9.4 Slinging points on the counterweight sections......................................................... 832 12.9.5 CHECKLIST: Rigging the counterweight.................................................................. 833 12.9.6 CHECKLIST: Unrigging the counterweight................................................................ 835 12.9.7 Assembling counterweight combination.................................................................. 836 Setting down the 2.3 t base plate........................................................................ 837 Setting down the top couterweight section................................................................ 837 Version 1................................................................................................ 838 Version 2................................................................................................ 846 Version 3................................................................................................ 850 12.9.8 Counterweight hoist unit.............................................................................. 858 Counterweight menu....................................................................................... 858 Extending/retracting the lifting cylinders............................................................... 859 Automatic mode rigging................................................................................... 861 Automatic mode unrigging................................................................................. 863 Cancel automatic mode.................................................................................... 864 12.9.9 Removing/installing the counterweight on the turntable................................................ 865 Removing................................................................................................. 865 Installing............................................................................................... 866 12.9.10 Setting down counterweight for driving............................................................... 867 Versions 1 and 3......................................................................................... 867 Version 2................................................................................................ 869 12.9.11 Slewing with rigged counterweight.................................................................... 869 12.10 Rigging work on the main boom.............................................................................. 871 12.10.1 Hook block on the bumper............................................................................. 871 Picking up the hook block................................................................................ 871 Attaching the hook block................................................................................. 872 12.10.2 Hook block on a separate vehicle..................................................................... 873 Picking up the hook block................................................................................ 874 Setting down the hook block.............................................................................. 874 12.10.3 Hook block, separable................................................................................ 876 Rigging for on- road driving............................................................................. 876 Rigging for crane operation.............................................................................. 877 12.10.4 Hook block with ballast plates....................................................................... 878 Removing................................................................................................. 878 Installing............................................................................................... 879 Information on crane operation........................................................................... 879 12.10.5 Reeving and unreeving the hoist rope................................................................. 880 Version A................................................................................................ 880 Version B................................................................................................ 881 Reeving the hoist rope................................................................................... 883 Unreeving hoist rope..................................................................................... 887 12.10.6 Possible reevings on the main boom................................................................... 888 With 6 head sheaves...................................................................................... 888 With 8 head sheaves...................................................................................... 891 With 9 head sheaves...................................................................................... 894 12.10.7 Installing/removing the lifting limit switch......................................................... 895 Installing the lifting limit switch...................................................................... 895 Removing the lifting limit switch........................................................................ 898 12.10.8 Locking/unlocking the lifting limit switch........................................................... 900 Locking.................................................................................................. 900 Removing the lock........................................................................................ 900 12.10.9 Anemometer and air traffic control light............................................................. 901 Installing............................................................................................... 901 Switching on/off......................................................................................... 902 Removing................................................................................................. 903 12.11 Other rigging work......................................................................................... 905 12.11.1 Railings on the turntable............................................................................ 905 12.11.2 Folding the mirrors in and out, and adjusting them................................................... 906 12.11.3 Slinging points for personal protective equipment.................................................... 907 12.11.4 Cameras for crane operation.......................................................................... 908 Camera on main boom...................................................................................... 908 Camera on the hoists..................................................................................... 911 Camera on the driver's cab............................................................................... 911 Operating the camera..................................................................................... 912 12.11.5 Step at the crane cab................................................................................ 913 13 Driving with a rigged truck crane................................................................................. 915 13.1 Route....................................................................................................... 915 13.2 Permissible rigging modes and axle loads.................................................................... 916 Axle load table.............................................................................................. 916 13.2.1 To drive without a load............................................................................... 919 13.2.2 To drive with a load.................................................................................. 919 13.2.3 Axle loads............................................................................................ 920 13.3 Before driving the rigged truck crane....................................................................... 921 13.3.1 Check the tyre pressures and wind speed............................................................... 921 13.3.2 Secure the superstructure against slewing............................................................. 921 13.3.3 Putting the truck crane on the wheels – with Raise axle function...................................... 922 13.3.4 Putting the truck crane on the wheels – with the outriggers........................................... 924 13.4 Driving from the driver's cab............................................................................... 927 13.4.1 Preparing to drive.................................................................................... 927 Transmission............................................................................................. 927 Switching on separate steering........................................................................... 927 Connections.............................................................................................. 927 13.4.2 Whilst driving........................................................................................ 928 13.4.3 After driving......................................................................................... 929 13.5 Driving from the crane cab.................................................................................. 931 13.5.1 Preparing to drive.................................................................................... 932 13.5.2 Opening/closing the driving menu...................................................................... 933 Opening the menu......................................................................................... 933 Selecting the operating mode............................................................................. 933 Crane's hydraulic system Driving mode.................................................................... 935 Closing menu............................................................................................. 935 13.5.3 Steering.............................................................................................. 936 Switching on............................................................................................. 936 Display and steering direction........................................................................... 936 Switching the steering direction......................................................................... 937 Displays when steering................................................................................... 937 Separate steering........................................................................................ 938 Normal steering mode..................................................................................... 941 13.5.4 Operating the transmission............................................................................ 942 Selecting the transmission mode.......................................................................... 942 13.5.5 Whilst driving........................................................................................ 943 DM and RM transmission mode.............................................................................. 943 Transmission mode D...................................................................................... 943 Warning messages......................................................................................... 943 13.5.6 Possible connections.................................................................................. 944 Longitudinal/ transverse differential locks.............................................................. 944 13.5.7 After driving......................................................................................... 946 14 Malfunctions during crane operation............................................................................... 947 14.1 Emergency stop switch....................................................................................... 947 14.2 What to do when malfunctions occur during crane operation................................................... 948 The load can be set down..................................................................................... 948 Load cannot be set down...................................................................................... 948 14.3 Warning and error messages.................................................................................. 949 Program version.............................................................................................. 949 14.3.1 Warning messages on the CCS display................................................................... 949 Meaning of the symbols................................................................................... 950 14.3.2 Error messages on the CCS display..................................................................... 954 14.3.3 Warning messages on the RCL display................................................................... 956 14.4 Troubleshooting............................................................................................. 961 14.4.1 Malfunctions on the engine............................................................................ 961 14.4.2 Malfunctions on the main hoist/auxiliary hoist........................................................ 961 14.4.3 Malfunctions in the hoist cameras..................................................................... 963 14.4.4 Malfunctions in the main boom camera.................................................................. 963 14.4.5 Malfunctions on the derricking gear................................................................... 964 14.4.6 Malfunctions in the telescoping mechanism............................................................. 965 14.4.7 Malfunctions on the slewing gear...................................................................... 966 14.4.8 Malfunctions on the counterweight hoist unit.......................................................... 968 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler............................................. 968 14.4.10 Malfunctions when operating with the hand-held control............................................... 969 14.4.11 Malfunctions when inclining the crane cab............................................................ 969 14.4.12 Malfunctions when raising the axles.................................................................. 969 14.4.13 Malfunctions of the outriggers....................................................................... 970 14.4.14 Malfunctions on the turntable lock................................................................... 970 14.4.15 Malfunctions on the CCS/RCL control units............................................................ 971 14.4.16 Malfunctions when driving from the crane cab......................................................... 971 14.4.17 Malfunctions on the CraneSTAR system................................................................. 972 14.5 Emergency operations and programs........................................................................... 975 14.5.1 Mechanical emergency activation for retracting........................................................ 976 Prior to the emergency operation, check.................................................................. 976 Procedure................................................................................................ 976 Mechanical emergency activation.......................................................................... 977 14.5.2 Telescoping emergency program......................................................................... 979 Telescoping emergency program menu....................................................................... 979 Determining the type of error............................................................................ 980 Error at the length indicator............................................................................ 981 Tables for approaching the locking points................................................................ 985 14.5.3 Entering the current telescoping...................................................................... 987 14.5.4 Emergency operation with the hand-held control........................................................ 989 To pre-select a power unit............................................................................... 990 Operating a power unit................................................................................... 990 Stopping movements....................................................................................... 991 Stopping movements in emergencies........................................................................ 992 Switch off the engine.................................................................................... 992 14.5.5 Notes on slewing in emergency operation............................................................... 992 For the Standard slewing range type...................................................................... 992 For the MAXbase slewing range type....................................................................... 994 14.5.6 Rotate for overridden slewing gear shutdown........................................................... 995 14.6 Hydraulic emergency operation with the hand pump............................................................ 997 14.6.2 Switching over the crane's hydraulic system........................................................... 998 14.6.3 Establishing the hydraulic circuits required.......................................................... 999 Releasing/ securing valves............................................................................... 999 Switching over valves....................................................................................1000 For lowering.............................................................................................1001 14.6.4 Performing emergency activation.......................................................................1002 14.6.5 After emergency activation............................................................................1003 14.7 Hydraulic emergency operation acc. to BGR 159...............................................................1005 14.7.1 Applications and function.............................................................................1005 14.7.2 CHECKLIST: Emergency operation........................................................................1007 14.7.3 CHECKLIST: After emergency operation..................................................................1008 14.7.4 Connecting/removing transformer – for self-sufficiency................................................1009 Connecting...............................................................................................1009 Removing.................................................................................................1010 14.7.5 Switching emergency operation on/off..................................................................1011 14.7.6 Connecting/removing transformer – for external energy source..........................................1012 14.7.7 Establishing the required hydraulic circuits..........................................................1013 Valves at the control panel..............................................................................1013 For lifting/ lowering....................................................................................1015 For slewing..............................................................................................1016 14.7.8 Performing emergency operation........................................................................1017 Slewing..................................................................................................1017 Derricking...............................................................................................1018 Lifting/lowering.........................................................................................1018 14.7.9 Emergency supply of another crane.....................................................................1019 For emergency supply.....................................................................................1019 After emergency supply...................................................................................1019 14.8 Fuses in the crane cab......................................................................................1021 Information on changing fuses................................................................................1021 Index....................................................................................................................1027 A....................................................................................................................1029 B....................................................................................................................1029 C....................................................................................................................1030 D....................................................................................................................1032 E....................................................................................................................1034 F....................................................................................................................1036 H....................................................................................................................1036 I....................................................................................................................1037 L....................................................................................................................1037 M....................................................................................................................1038 O....................................................................................................................1039 P....................................................................................................................1041 R....................................................................................................................1041 S....................................................................................................................1042 T....................................................................................................................1043 V....................................................................................................................1045 W....................................................................................................................1045
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