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Grove Crane GMK 5150 Operating Manual 3302776 – PDF DOWNLOAD
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Description
Grove Crane GMK 5150 Operating Manual 3302776 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5150 Operating Manual 3302776 – PDF DOWNLOAD
Language : English
Pages : 1032
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 5150 Operating Manual 3302776 – PDF DOWNLOAD
Overview:
General instructions:
- This operating manual contains illustrations of the GMK5150L with five telescopic sections.
- The GMK5150 has four telescopic sections (1). The illustrations have only been altered where
relevant for the operation.
Basic safety instructions:
Intended use:
The GMK5150 truck crane is constructed in accordance with the latest tech- nology and the
recognised safety regulations. Nevertheless, the operator or third parties can still be endangered
and the crane or other property put at risk while using it.
- The truck crane may be modified only with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK5150 truck crane may be used only when it is in perfect technical condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK5150 truck crane may only be operated without the correspond- ing special equipment within
the permitted temperature range;
à Technical data, p. 1 – 7.
The GMK5150 truck crane is designed solely for lifting loads which are within the permitted GMK5150
lifting capacities. The load must be slung as prescribed to a hook block which is positioned
vertically over the load prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating manual(s), the lifting
capacity table, the outrigger pressure table and the safety manual
– adhering to the inspection and maintenance requirements specified in the maintenance manual.
- The GMK5150 may only be operated with parts of equipment which have been approved by Manitowoc
Crane Group Germany GmbH and which are labelled with the serial number of the GMK5150. - The manufacturer is not liable for any damage caused by improper or unau-
thorized use of the GMK5150 truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 5150 Operating Manual 3302776 – PDF DOWNLOAD
Operating manual............................................................................................................. 1 Additional pages......................................................................................................... 3 Outrigger spans...................................................................................................... 3 Driving from the crane cab........................................................................................... 5 Table of contens......................................................................................................... 9 General.................................................................................................................. 39 1 Overview........................................................................................................... 39 1.1 General instructions......................................................................................... 39 1.2 Accidents.................................................................................................... 39 1.3 Branch offices............................................................................................... 41 1.3.1 Manitowoc Crane Care................................................................................... 41 1.3.2 Dealer list............................................................................................ 41 1.4 Warranty specifications...................................................................................... 41 1.5 Terms used................................................................................................... 42 1.6 Technical data............................................................................................... 45 1.6.1 Maximum lifting capacity (ASME B 30.5)................................................................. 45 1.6.2 Dimensions and weights of the truck crane, axle loads.................................................. 46 Dimensions............................................................................................... 47 Weight and axle loads.................................................................................... 47 1.6.3 Dimensions and weights of removable parts.............................................................. 48 Spare wheel.............................................................................................. 48 Outrigger................................................................................................ 48 Main boom................................................................................................ 48 Hook blocks and hook tackle.............................................................................. 49 Auxiliary hoist.......................................................................................... 51 Counterweight parts...................................................................................... 52 1.6.4 Carrier................................................................................................ 55 Engine................................................................................................... 55 Transmission............................................................................................. 55 Transfer case............................................................................................ 55 Axle lines............................................................................................... 55 Steering................................................................................................. 56 Tyres.................................................................................................... 56 Turning turning radii.................................................................................... 56 Outrigger................................................................................................ 57 Electrical system........................................................................................ 58 Tool..................................................................................................... 58 Towing couplings......................................................................................... 58 Driving speeds........................................................................................... 58 Climbing ability......................................................................................... 58 1.6.5 Superstructure......................................................................................... 59 Main hoist............................................................................................... 59 Auxiliary hoist.......................................................................................... 59 Slewing gears............................................................................................ 59 Derricking gear.......................................................................................... 59 Main boom................................................................................................ 60 Lattice extension........................................................................................ 60 Operating speeds......................................................................................... 60 1.7 Documentation supplied....................................................................................... 61 1.7.1 Questions on documentation............................................................................. 62 1.8 Notes on the operating manual................................................................................ 63 1.8.1 What do the symbols used mean?......................................................................... 63 1.8.2 How is the operating manual structured?................................................................ 65 Division................................................................................................. 65 Structure of the chapters................................................................................ 65 Structure of the pages................................................................................... 66 1.8.3 How do I find the information I need?.................................................................. 67 Cross-references example................................................................................. 68 1.8.4 What information is available for operations planning?................................................. 70 1.9 Conversion table for US measuring units...................................................................... 71 1.10 Training - Information...................................................................................... 73 1.11 Identification.............................................................................................. 74 1.12 EC Declaration of Conformity................................................................................ 76 2 Basic safety instructions.......................................................................................... 77 2.1 Intended use................................................................................................. 77 2.1.1 Improper use........................................................................................... 78 2.2 Organisational measures...................................................................................... 79 2.3 Personnel qualifications..................................................................................... 81 2.4 Safety instructions for driving the truck crane.............................................................. 82 2.5 Safety instructions for crane operation...................................................................... 83 2.6 Instructions on transporting persons......................................................................... 86 Equipment for lifting persons................................................................................ 86 Personnel.................................................................................................... 86 Operation.................................................................................................... 87 Truck crane.................................................................................................. 88 Driving.................................................................................................................. 89 3 Operating elements for driving..................................................................................... 89 3.1 Overview of the operating elements........................................................................... 89 3.1.1 On the outside of the truck crane...................................................................... 90 3.1.2 Driver's cab........................................................................................... 94 Front overview........................................................................................... 94 Rear overview............................................................................................ 96 Behind the cover......................................................................................... 97 3.1.3 Steering column/steering wheel......................................................................... 98 3.1.4 Instrument panel....................................................................................... 99 Left/right............................................................................................... 99 Middle................................................................................................... 100 3.1.5 Transmission operating elements........................................................................ 102 3.1.6 On-board computer...................................................................................... 103 3.1.7 Tachograph............................................................................................. 104 3.1.8 Heating and air-conditioning system.................................................................... 105 Standard................................................................................................. 105 Auxiliary water heating system........................................................................... 106 Auxiliary air heater..................................................................................... 107 3.1.9 CCS control unit....................................................................................... 109 3.1.10 CCS – menu-dependent displays......................................................................... 110 3.1.11 CCS – Start menu...................................................................................... 111 3.1.12 CCS – Overview menu groups............................................................................ 112 3.1.13 Carrier menu group.................................................................................... 114 Suspension/level adjustment menu......................................................................... 115 Driving menu............................................................................................. 116 3.1.14 Settings menu group................................................................................... 117 Set display brightness and date/time menu................................................................ 118 Switch units menu........................................................................................ 119 3.1.15 Menu group Information................................................................................ 120 Operating hours menu..................................................................................... 121 Engine/transmission error menu........................................................................... 122 Crane operation error menu............................................................................... 123 3.1.16 Various controls menu group........................................................................... 124 3.1.17 Emergency operations menu group....................................................................... 125 3.1.18 Outrigger control units............................................................................... 126 3.2 Short description of the operating elements.................................................................. 127 3.2.1 Definition of information relating to directions of movement........................................... 128 Basic rule............................................................................................... 128 3.2.2 General rules for buttons and symbols on the display................................................... 129 3.2.3 Engine................................................................................................. 130 Steering column.......................................................................................... 130 On the steering wheel.................................................................................... 130 Instrument panel......................................................................................... 131 3.2.4 AdBlue system.......................................................................................... 132 Instrument panel......................................................................................... 132 CCS display.............................................................................................. 133 3.2.5 Battery master switch.................................................................................. 133 3.2.6 Electrical system...................................................................................... 134 3.2.7 Crane control CCS...................................................................................... 135 3.2.8 Transmission........................................................................................... 137 Transmission control unit................................................................................ 137 Display, driving mode.................................................................................... 139 3.2.9 Reverse camera......................................................................................... 140 3.2.10 BirdView system 270°.................................................................................. 141 3.2.11 Transfer case......................................................................................... 143 3.2.12 Final drive........................................................................................... 145 3.2.13 Brakes................................................................................................ 146 Service brake............................................................................................ 146 Additional brakes........................................................................................ 146 Parking brake............................................................................................ 147 3.2.14 Steering/separate steering............................................................................ 148 Instrument panel......................................................................................... 148 CCS display.............................................................................................. 150 3.2.15 Suspension............................................................................................ 152 CCS display.............................................................................................. 152 3.2.16 Lighting/windscreen wipers/horn....................................................................... 153 Steering column.......................................................................................... 153 Steering wheel........................................................................................... 153 Instrument panel......................................................................................... 153 CCS display.............................................................................................. 155 Roof..................................................................................................... 155 3.2.17 Level adjustment system............................................................................... 156 3.2.18 Tachograph/speedometer................................................................................ 158 Tachograph............................................................................................... 158 Cover.................................................................................................... 158 Speedometer.............................................................................................. 158 3.2.19 Diagnostics........................................................................................... 159 3.2.20 Push-up roof.......................................................................................... 159 3.2.21 On-board computer..................................................................................... 160 3.2.22 Front flap............................................................................................ 161 3.2.23 Windows and doors..................................................................................... 162 Window winder............................................................................................ 162 Doors.................................................................................................... 163 3.2.24 Access ladders and ladders............................................................................ 165 4 Starting the engine for driving / switching it off................................................................. 169 4.1 Starting the engine from the driver's cab.................................................................... 169 4.1.1 CHECKLIST: Starting the engine......................................................................... 169 4.1.2 CHECKLIST: At low temperatures......................................................................... 172 4.1.3 Filling up............................................................................................. 173 Fuel tank................................................................................................ 173 AdBlue tank.............................................................................................. 175 4.1.4 Checks before starting the engine...................................................................... 176 At the hydraulic tank.................................................................................... 176 Battery master switch.................................................................................... 177 Checking the hand-held control........................................................................... 177 4.1.5 Switch the ignition on................................................................................. 177 4.1.6 Lamp test/equalisation of the switching states......................................................... 178 Lamp test................................................................................................ 178 Switching state alignment................................................................................ 178 4.1.7 Display – setting the brightness....................................................................... 179 4.1.8 Starting the engine.................................................................................... 181 4.1.9 Checks after starting the engine....................................................................... 183 Start menu and on-board computer......................................................................... 183 Instrument panel......................................................................................... 184 4.1.10 Setting the idling speed.............................................................................. 185 4.2 Switch off the engine........................................................................................ 186 4.2.1 At the ignition lock and with the outrigger control units.............................................. 186 After switching off...................................................................................... 186 4.2.2 Using the emergency stop switches...................................................................... 187 Resetting the emergency stop switch...................................................................... 187 4.3 Air intake inhibitor......................................................................................... 188 Opening the air intake inhibitor............................................................................. 188 5 Driving............................................................................................................ 189 5.1 Before driving............................................................................................... 189 5.1.1 CHECKLIST: checks before on-road driving............................................................... 189 5.1.2 Check the condition of the truck crane................................................................. 195 Electrical system........................................................................................ 195 Adjusting the mirrors.................................................................................... 195 Warning plates for vehicle width......................................................................... 197 Checking the vehicle height.............................................................................. 197 Supply pressure.......................................................................................... 198 Parking brake............................................................................................ 199 Third brake light........................................................................................ 200 5.1.3 Adjusting the seat and the steering column............................................................. 201 Adjusting the driver's seat.............................................................................. 201 Adjusting the passenger seat............................................................................. 202 Adjusting the steering column............................................................................ 203 5.1.4 Switching the suspension on/off........................................................................ 204 Open menu................................................................................................ 204 Switching the suspension on.............................................................................. 205 Switching the suspension off............................................................................. 205 5.1.5 Setting the tachograph................................................................................. 206 Prerequisites............................................................................................ 206 In the event of malfunctions............................................................................. 206 Setting the tachograph................................................................................... 207 5.1.6 Setting the time....................................................................................... 211 5.1.7 Displaying and resetting operating hours............................................................... 212 5.2 Operating the transmission................................................................................... 213 5.2.1 Switching on........................................................................................... 213 5.2.2 Switching the transmission to the neutral position..................................................... 214 5.2.3 Selecting the direction of travel and starting gear.................................................... 215 Selecting the driving direction.......................................................................... 215 Selecting the starting gear.............................................................................. 216 5.2.4 Changing the operating mode............................................................................ 217 Changing to automatic mode............................................................................... 217 Change to manual mode.................................................................................... 217 5.2.5 Starting............................................................................................... 218 5.2.6 Driving and changing gears............................................................................. 219 In automatic operating mode.............................................................................. 219 In manual operating mode................................................................................. 220 5.2.7 Changing the driving direction......................................................................... 221 5.2.8 Stopping............................................................................................... 221 Stopping for longer periods.............................................................................. 221 5.2.9 On the roller type dynamometer......................................................................... 222 5.2.10 Preheating transmission............................................................................... 222 5.3 Driving the truck crane and switching it off................................................................. 223 5.3.1 Checks whilst driving.................................................................................. 223 Brakes................................................................................................... 223 ABS system............................................................................................... 223 Steering................................................................................................. 224 Warning messages......................................................................................... 224 Monitoring elements...................................................................................... 225 5.3.2 Cruise control......................................................................................... 226 Switching on............................................................................................. 226 Switching off............................................................................................ 227 5.3.3 Temposet............................................................................................... 228 Switching on............................................................................................. 228 Switching off............................................................................................ 228 5.3.4 Driving downhill....................................................................................... 229 Starting................................................................................................. 229 Checks when driving downhill............................................................................. 230 Downshifting............................................................................................. 230 Additional brakes........................................................................................ 231 5.3.5 Driving uphill......................................................................................... 232 Starting................................................................................................. 232 Driving.................................................................................................. 232 5.3.6 Overriding torque reduction............................................................................ 233 5.3.7 Switching the truck crane off.......................................................................... 234 Secure it against rolling away........................................................................... 234 When stationary for more than 8 hours.................................................................... 235 5.3.8 Fold-up berth.......................................................................................... 236 5.4 Off-road driving............................................................................................. 237 Adjustments to the transmission.............................................................................. 237 Connections.................................................................................................. 237 Changing the vehicle level................................................................................... 237 Rocking the vehicle free and towing.......................................................................... 237 5.4.1 Transfer case – switching the off-road gear on/off..................................................... 238 5.4.2 Longitudinal and transverse differential locks......................................................... 239 5.4.3 Operating the level adjustment system.................................................................. 241 Open menu................................................................................................ 241 Setting the on-road level................................................................................ 242 Pre-selecting suspension struts.......................................................................... 242 Changing the vehicle level............................................................................... 243 Viewing the current inclination.......................................................................... 244 Exiting the menu......................................................................................... 244 5.4.4 Freeing truck crane stuck in terrain................................................................... 245 Rocking the truck crane free............................................................................. 245 Towing free forwards..................................................................................... 246 Towing free to the rear.................................................................................. 246 5.5 Separate steering............................................................................................ 247 5.5.1 Switching to separate steering......................................................................... 248 5.5.2 Switching to normal steering mode...................................................................... 251 5.5.3 Switching units of measure............................................................................. 252 5.6 Heating and air-conditioning system.......................................................................... 253 5.6.1 Standard heating system................................................................................ 253 Switching on............................................................................................. 253 Heating.................................................................................................. 253 Air distribution......................................................................................... 254 Examples................................................................................................. 255 Switching off............................................................................................ 255 5.6.2 Air-conditioning system................................................................................ 256 Notes.................................................................................................... 256 Switching on/off......................................................................................... 256 Cooling.................................................................................................. 257 Drying................................................................................................... 257 5.6.3 Auxiliary water heating system......................................................................... 258 Preheating the engine.................................................................................... 258 Preheating the driver's cab.............................................................................. 259 Switching on............................................................................................. 259 Setting the date and time................................................................................ 261 Storing the heating start................................................................................ 262 5.6.4 Auxiliary air heater................................................................................... 264 Switching on............................................................................................. 264 Setting the heating level................................................................................ 265 Setting the day and time................................................................................. 266 Setting the preselection time............................................................................ 266 Preselection times Delete................................................................................ 268 Switching off............................................................................................ 268 5.7 Radio........................................................................................................ 268 5.8 Towing a trailer............................................................................................. 269 Effects on the axle loads.................................................................................... 269 Coupling the trailer......................................................................................... 270 Connecting the supply lines.................................................................................. 271 Removing supply lines........................................................................................ 272 Uncoupling the trailer....................................................................................... 272 Checking the braking force................................................................................... 274 6 Driving modes and rigging for on-road driving...................................................................... 275 6.1 Driving modes................................................................................................ 275 Information about the axle loads............................................................................. 275 6.1.1 How to use the tables.................................................................................. 276 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs)..................................................... 277 Tyres 385/95 R25......................................................................................... 277 Tyres 445/95 R25......................................................................................... 278 Tyres 525/80 R25......................................................................................... 279 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs)................................... 280 6.2 Weighing the truck crane..................................................................................... 281 Axle groups.................................................................................................. 282 Weighing procedure........................................................................................... 283 Evaluation................................................................................................... 284 6.3 Rigging work for driving with a dolly........................................................................ 285 6.3.1 Switching on the slewing gear freewheel................................................................ 286 6.3.2 Switching on the boom floating position................................................................ 287 6.3.3 Switching on boom pre-tensioning....................................................................... 288 6.3.4 Raising/lowering the 3rd axle line for dolly operation................................................. 289 6.4 Rigging the main boom........................................................................................ 291 Additional equipment required................................................................................ 291 6.4.1 CHECKLIST: Removing the main boom...................................................................... 292 Prerequisites............................................................................................ 292 Checklist................................................................................................ 292 6.4.2 CHECKLIST: Mounting the main boom...................................................................... 295 Prerequisites............................................................................................ 295 Checklist................................................................................................ 295 6.4.3 Disconnecting/connecting hydraulics/electrical......................................................... 298 6.4.4 Derricking cylinder support............................................................................ 300 6.4.5 Slinging the main boom................................................................................. 300 Marking.................................................................................................. 300 Attach lifting gear...................................................................................... 301 Removing the sling gear.................................................................................. 302 6.4.6 Switching the pressure relief on/off................................................................... 303 6.4.7 Retracting/fitting the derricking cylinder head pin.................................................... 304 Operating the lifting device............................................................................. 304 Pulling the derricking cylinder head axle................................................................ 304 Fitting the derricking cylinder head axle................................................................ 305 6.4.8 Extending/retracting the boom pivot pin................................................................ 306 Pulling out the pivot pin................................................................................ 306 Pushing the pivot pin in................................................................................. 308 6.4.9 Transporting the main boom............................................................................. 309 6.4.10 Securing/releasing the derricking cylinder............................................................ 309 6.4.11 Aligning the connecting points........................................................................ 310 6.4.12 Inspections after main boom mounting.................................................................. 311 6.5 Rigging the auxiliary hoist.................................................................................. 313 6.5.1 Slinging the auxiliary hoist........................................................................... 313 6.5.2 CHECKLIST: Installing the auxiliary hoist.............................................................. 314 6.5.3 CHECKLIST: Removing the auxiliary hoist................................................................ 315 6.5.4 Making/breaking the connection between the auxiliary hoist and the turntable........................... 316 6.5.5 Establishing/disconnecting the hydraulic connections................................................... 317 6.5.6 Disconnecting/establishing the electrical connection................................................... 318 6.5.7 Making/breaking the connection to the central lubrication.............................................. 319 6.5.8 Transporting the auxiliary hoist....................................................................... 320 6.5.9 Check that the auxiliary hoist is functioning properly................................................. 321 Slewing direction........................................................................................ 321 Slewing indicator........................................................................................ 321 6.5.10 Rigging aid for the hoist rope........................................................................ 322 6.6 Installing/removing the outrigger beams...................................................................... 325 6.6.1 CHECKLIST: Removing the outrigger beams................................................................ 326 6.6.2 CHECKLIST: Installing the outrigger beams.............................................................. 328 6.6.3 Centre of gravity data................................................................................. 330 6.6.4 Preparations – for removal............................................................................. 330 6.6.5 Preparations – on the truck crane...................................................................... 331 Prerequisites............................................................................................ 331 6.6.6 Removing/attaching outrigger pads...................................................................... 332 Removing the outrigger pads.............................................................................. 332 Attaching the outrigger pads............................................................................. 333 6.6.7 Disconnecting/establishing hydraulic connection........................................................ 334 6.6.8 Disconnecting/establishing the electrical connection................................................... 335 6.6.9 Unscrewing/screwing in the spacers..................................................................... 336 Unscrewing............................................................................................... 336 Screwing in.............................................................................................. 337 6.6.10 Disconnecting/establishing the connections to the supporting box...................................... 338 6.6.11 Pulling out/Inserting the outrigger beam.............................................................. 338 Extending the outrigger beam............................................................................. 338 Inserting the outrigger beam............................................................................. 340 6.6.12 Transporting the outrigger beams...................................................................... 342 6.6.13 Note on error messages with removed outrigger beams................................................... 342 7 Transport.......................................................................................................... 343 7.1 Transport with transport vehicle............................................................................. 343 7.1.1 CHECKLIST: Checks before transport..................................................................... 344 7.1.2 Drive the truck crane on to the transport vehicle...................................................... 346 Driving on............................................................................................... 347 Lashing.................................................................................................. 347 7.2 Transport by ship............................................................................................ 348 8 Malfunctions in driving mode....................................................................................... 349 8.1 Emergency stop switch........................................................................................ 349 8.2 Procedure during malfunctions................................................................................ 350 8.2.1 What to do when a malfunction occurs in road traffic................................................... 350 8.2.2 Procedure during engine malfunctions................................................................... 351 8.2.3 Procedure during transmission malfunctions............................................................. 352 8.3 Warning and error messages................................................................................... 353 8.3.1 Warning or malfunction messages on the instrument panel................................................ 353 Meaning of the lamps..................................................................................... 353 8.3.2 Warning and malfunction messages on the on-board computer display...................................... 357 Messages................................................................................................. 357 Symbols.................................................................................................. 358 8.3.3 Warning messages on the CCS display.................................................................... 361 Symbols in the display area.............................................................................. 361 8.3.4 Error messages on the CCS display...................................................................... 365 Exiting the menu......................................................................................... 366 Special error messages................................................................................... 366 8.4 Troubleshooting.............................................................................................. 367 8.4.1 Malfunctions on the engine............................................................................. 367 When operating with the dual tank........................................................................ 369 8.4.2 Faults on the Adblue system............................................................................ 369 8.4.3 Differential lock malfunctions......................................................................... 370 8.4.4 Transfer case malfunctions............................................................................. 370 8.4.5 Malfunctions in the transmission....................................................................... 371 8.4.6 Malfunctions of the steering........................................................................... 372 8.4.7 Malfunctions of the service brake...................................................................... 373 8.4.8 Malfunctions on the suspension......................................................................... 373 8.4.9 Malfunctions of the level adjustment system............................................................ 374 8.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler............................................. 374 8.5 Emergency operation and breakdown assistance................................................................. 375 8.5.1 Starting the truck crane externally.................................................................... 375 8.5.2 Battery charger........................................................................................ 376 Prerequisites............................................................................................ 376 8.5.3 Towing the truck crane................................................................................. 377 In the case of engine/transmission damage................................................................ 377 Longer towing distances.................................................................................. 380 Tow starting............................................................................................. 380 8.5.4 Wheel change........................................................................................... 381 Removing a damaged wheel................................................................................. 382 On the spare wheel holder................................................................................ 382 Mounting a wheel......................................................................................... 384 8.5.5 Inflating the tyres yourself........................................................................... 385 Connecting the filling hose.............................................................................. 385 Inflating the tyres...................................................................................... 386 Remove the filling hose.................................................................................. 386 8.5.6 Emergency operation, steering 3rd and 4th axle lines................................................... 387 Performing emergency operation........................................................................... 388 After emergency operation................................................................................ 390 8.6 Tilting/lowering the driver's cab............................................................................ 391 8.6.1 Prerequisites and information on tilting............................................................... 391 8.6.2 Tilting and lowering the driver's cab.................................................................. 392 Operating the hand pump.................................................................................. 392 Tilting the driver's cab................................................................................. 393 Lowering the driver's cab................................................................................ 394 8.7 Fuses on the carrier......................................................................................... 397 Information on changing fuses................................................................................ 397 8.7.1 Fuses in the driver's cab.............................................................................. 398 8.7.2 Fuses in the battery box............................................................................... 404 Crane Operation.......................................................................................................... 405 9 Operating elements for crane operation............................................................................. 405 9.1 Overview of the operating elements........................................................................... 405 9.1.1 Exterior of the truck crane............................................................................ 406 9.1.2 Crane cab.............................................................................................. 410 Side panel............................................................................................... 412 Crane cab, rear.......................................................................................... 414 9.1.3 Control panels......................................................................................... 416 Left..................................................................................................... 416 Right.................................................................................................... 417 9.1.4 Control lever assignment............................................................................... 418 Version 1................................................................................................ 418 Version 2................................................................................................ 419 9.1.5 CCS control unit....................................................................................... 420 9.1.6 Menu-independent displays.............................................................................. 422 9.1.7 CCS – Start menu....................................................................................... 423 RCL display.............................................................................................. 424 Display Slewing ranges/working radii..................................................................... 425 9.1.8 CCS – Overview menu groups............................................................................. 426 9.1.9 Superstructure menu group.............................................................................. 430 Superstructure lock sub-menu............................................................................. 431 Counterweight menu....................................................................................... 432 9.1.10 Menu group outrigger/driving.......................................................................... 433 Outrigger menu........................................................................................... 434 Outrigger cylinders menu................................................................................. 436 Driving menu............................................................................................. 438 9.1.11 RCL/Telescoping menu group............................................................................ 441 Menu enter rigging mode/ telescope....................................................................... 442 Pre-selection telescoping menu........................................................................... 446 Lifting capacity tables menu............................................................................. 448 Telescoping semi- automation menu........................................................................ 449 Manual telescoping menu.................................................................................. 450 9.1.12 Working range limiter menu group...................................................................... 451 Overall height menu...................................................................................... 452 Working radius menu...................................................................................... 453 Slewing angle menu....................................................................................... 454 Hoist rope travel limitation menu........................................................................ 455 9.1.13 Information 1 menu group.............................................................................. 456 Hydraulic pressure and fuel consumption menu............................................................. 457 9.1.14 Heating/Engine/Additional equipment menu group........................................................ 458 Economy menu............................................................................................. 459 Remote control menu...................................................................................... 460 Heating/air-conditioning menu............................................................................ 461 Spotlights menu.......................................................................................... 462 9.1.15 Telescoping emergency program menu group.............................................................. 463 Telescoping emergency program menu....................................................................... 464 Unknown telescoping menu................................................................................. 466 9.1.16 Menu group, settings.................................................................................. 467 Crane cab menu........................................................................................... 468 Set display brightness and date/ time menu............................................................... 469 Switch units menu........................................................................................ 470 Set control lever characteristic curve menu.............................................................. 471 Power unit speeds menu................................................................................... 472 9.1.17 Information 2 menu group.............................................................................. 473 Operating hours menu..................................................................................... 474 Engine/transmission error menu........................................................................... 475 Crane operation error menu............................................................................... 476 Program version menu..................................................................................... 477 9.1.18 Various controls...................................................................................... 479 9.1.19 RCL control unit...................................................................................... 480 9.1.20 Menu-independent displays............................................................................. 481 9.1.21 RCL – menus........................................................................................... 482 Monitoring menu.......................................................................................... 482 Lifting capacity tables menu............................................................................. 484 Datalogger menu.......................................................................................... 485 9.1.22 Hand-held control..................................................................................... 487 9.1.23 Outriggers control units.............................................................................. 489 Menu-independent buttons................................................................................. 489 Outrigger menu........................................................................................... 490 Raise axle menu.......................................................................................... 492 9.2 Short description of the operating elements.................................................................. 493 9.2.1 Definition of information relating to directions of movement........................................... 493 Basic rule............................................................................................... 493 9.2.2 General rules for buttons and symbols on the display................................................... 494 9.2.3 Engine................................................................................................. 495 Side panel............................................................................................... 495 Left control lever....................................................................................... 495 Economy mode menu........................................................................................ 496 9.2.4 AdBlue system.......................................................................................... 496 CCS display.............................................................................................. 496 9.2.5 Seat contact switch and dead man's switch.............................................................. 498 9.2.6 Crane control CCS...................................................................................... 499 9.2.7 Outrigger – crane cab.................................................................................. 504 Control panels........................................................................................... 504 CCS display.............................................................................................. 505 9.2.8 Outrigger control units................................................................................ 507 General information...................................................................................... 507 Outrigger menu........................................................................................... 508 9.2.9 Raise axle............................................................................................. 510 9.2.10 Inclination indicators................................................................................ 512 9.2.11 Outrigger pressure displays........................................................................... 513 Outrigger menu........................................................................................... 513 Outriggers control units................................................................................. 513 9.2.12 Anemometer displays................................................................................... 513 9.2.13 Counterweight menu.................................................................................... 514 9.2.14 Main hoist............................................................................................ 518 Control panels........................................................................................... 518 CCS display.............................................................................................. 518 9.2.15 Auxiliary hoist....................................................................................... 520 Control panels........................................................................................... 520 CCS display.............................................................................................. 521 9.2.16 Slewing gear.......................................................................................... 522 Control panels........................................................................................... 522 CCS display.............................................................................................. 523 9.2.17 Derricking gear....................................................................................... 524 Control panels........................................................................................... 524 CCS display.............................................................................................. 525 Side panel............................................................................................... 525 9.2.18 Telescoping mechanism................................................................................. 526 Control panels........................................................................................... 526 CCS display.............................................................................................. 527 Telescoping semi- automation menu........................................................................ 527 Manual telescoping menu.................................................................................. 529 9.2.19 Hydraulic system...................................................................................... 532 9.2.20 Superstructure lock/house lock menu................................................................... 533 Superstructure lock...................................................................................... 533 Houselock................................................................................................ 535 9.2.21 Remote control........................................................................................ 536 9.2.22 Rated capacity limiter (RCL).......................................................................... 537 CCS display.............................................................................................. 537 RCL display.............................................................................................. 546 RCL override – version A................................................................................. 547 RCL override – version B................................................................................. 548 9.2.23 Electrical system..................................................................................... 549 9.2.24 Lighting, windscreen wiper/washing system............................................................. 550 Lighting................................................................................................. 550 Windscreen wiper/washing system.......................................................................... 552 Horn..................................................................................................... 553 9.2.25 Hand-held control..................................................................................... 554 Sockets for hand- held control........................................................................... 554 Engine control panel..................................................................................... 555 Horn..................................................................................................... 555 9.2.26 Windows and doors..................................................................................... 558 window................................................................................................... 558 rear window.............................................................................................. 558 Crane cab door........................................................................................... 559 9.2.27 Diagnostics........................................................................................... 560 9.2.28 Other................................................................................................. 560 9.3 Short description of the operating elements – driving from the crane cab..................................... 561 9.3.1 Driving menu........................................................................................... 561 9.3.2 Transmission........................................................................................... 563 9.3.3 Final drive............................................................................................ 565 9.3.4 Brakes................................................................................................. 566 CCS display.............................................................................................. 566 Side panel from above.................................................................................... 566 9.3.5 Steering............................................................................................... 567 CCS display.............................................................................................. 568 Control panels........................................................................................... 570 10 Starting/switching off the engine – for crane operation........................................................... 571 10.1 When starting the engine for the first time in the day...................................................... 571 10.2 Starting the engine – from the crane cab.................................................................... 573 10.2.1 Check the fuel level and AdBlue level................................................................. 573 Fuel..................................................................................................... 573 AdBlue................................................................................................... 573 10.2.2 Checks before starting the engine..................................................................... 574 Checks on the carrier.................................................................................... 574 Checking the hand-held control........................................................................... 574 At the hydraulic tank.................................................................................... 574 10.2.3 Switching the ignition on............................................................................. 575 10.2.4 Comparison of switching states........................................................................ 576 10.2.5 Display – setting the brightness...................................................................... 576 10.2.6 Starting the engine................................................................................... 577 10.2.7 Checks after starting the engine...................................................................... 578 10.2.8 Setting the idling speed.............................................................................. 579 10.3 Starting the engine – with the hand-held control............................................................ 580 10.4 Switch off the engine....................................................................................... 581 10.4.1 At the ignition lock and with hand-held control....................................................... 581 After switching off...................................................................................... 581 10.4.2 With the idling button................................................................................ 581 10.4.3 Using the emergency stop switches..................................................................... 582 Emergency stop switch, resetting......................................................................... 582 11 Crane operation................................................................................................... 583 11.1 Before operating the crane.................................................................................. 583 11.1.1 CHECKLIST: Checks before operating the crane.......................................................... 583 11.1.2 Check the condition of the truck crane................................................................ 587 Fuel tank auxiliary heater............................................................................... 587 Visual inspection........................................................................................ 587 Checking the position of the hoist ropes................................................................. 588 Checking the electrical system........................................................................... 589 11.1.3 Adjusting the crane cab seat and front control panel.................................................. 590 Crane cab seat........................................................................................... 590 Front control panel...................................................................................... 591 11.1.4 Checking the safety equipment......................................................................... 592 Rated capacity limiter................................................................................... 592 Lifting limit switch..................................................................................... 592 Emergency stop switch.................................................................................... 593 Seat contact switch...................................................................................... 594 11.1.5 Earthing the load..................................................................................... 595 11.1.6 Preheating hydraulic oil.............................................................................. 596 Prerequisites............................................................................................ 596 Preheating............................................................................................... 596 11.1.7 Locking/unlocking the superstructure.................................................................. 597 Locking points........................................................................................... 597 Lock the superstructure.................................................................................. 598 Unlocking the superstructure............................................................................. 598 11.1.8 Switching the houselock on/off........................................................................ 599 Switching on the houselock............................................................................... 599 Switching off the houselock.............................................................................. 601 11.2 Standard slewing range type................................................................................. 603 11.2.1 Permissible slewing ranges and working positions...................................................... 603 360° slewing range....................................................................................... 603 Working position 0° to the rear.......................................................................... 603 180° to the front rigging position....................................................................... 603 11.3 MAXbase slewing range type.................................................................................. 605 11.3.1 Specifications in the lifting capacity tables......................................................... 606 11.3.2 Enabled slewing ranges................................................................................ 607 11.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables.... 610 11.4 Operation of the rated capacity limiter..................................................................... 611 11.4.1 Switch on the RCL..................................................................................... 612 Switching on............................................................................................. 612 11.4.2 Enter rigging mode.................................................................................... 614 Notes on Input........................................................................................... 614 Enter the slewing range type............................................................................. 615 Entering individual components........................................................................... 616 Entering the RCL code.................................................................................... 622 11.4.3 Pre-selecting telescoping............................................................................. 622 11.4.4 Confirm the rigging mode and lifting capacity table................................................... 623 Slewing range type Standard.............................................................................. 623 Slewing range type MAXbase............................................................................... 625 11.4.5 Checks before operating the crane..................................................................... 627 Monitoring menu.......................................................................................... 627 Checking the rigging mode................................................................................ 627 Hoist checking........................................................................................... 629 11.4.6 Display during the crane operation.................................................................... 631 On the RCL display....................................................................................... 631 On the CCSdisplay........................................................................................ 635 11.4.7 RCL early warning..................................................................................... 639 11.4.8 RCL shutdown.......................................................................................... 639 Shutdown due to overload................................................................................. 639 11.4.9 Displaying the lifting capacity tables................................................................ 641 Slewing range type Standard.............................................................................. 641 Slewing range type MAXbase............................................................................... 643 11.4.10 RCL override – version A............................................................................. 645 Overview status display.................................................................................. 645 When rigging............................................................................................. 646 To raise the boom........................................................................................ 647 In emergencies........................................................................................... 648 11.4.11 RCL override – version B............................................................................. 649 11.4.12 Datalogger........................................................................................... 650 Export data.............................................................................................. 650 Display the data......................................................................................... 651 11.5 Crane operation with main boom.............................................................................. 655 11.5.1 Checks during crane operation......................................................................... 655 Horizontal alignment..................................................................................... 655 Safe distances........................................................................................... 655 Checking the wind speed.................................................................................. 656 11.5.2 Main hoist............................................................................................ 657 Switching on the main hoist.............................................................................. 658 Lifting and lowering..................................................................................... 659 Maximum permissible hoist rope speed..................................................................... 660 Switching off the main hoist............................................................................. 660 11.5.3 Auxiliary hoist....................................................................................... 661 Switching on the auxiliary hoist......................................................................... 661 Lifting and lowering..................................................................................... 662 Maximum permissible hoist rope speed..................................................................... 663 Switching off the auxiliary hoist........................................................................ 663 11.5.4 Lifting limit switch and lowering limit switch........................................................ 664 Lifting limit switch..................................................................................... 664 Lowering limit switch.................................................................................... 666 11.5.5 Derricking gear....................................................................................... 667 Switching on the derricking gear......................................................................... 667 Raising and lowering..................................................................................... 668 Maximum derricking speed................................................................................. 669 Re-enable raising function............................................................................... 669 Switching off the derricking gear........................................................................ 670 Lowering the main boom to a horizontal position.......................................................... 670 11.5.6 Telescoping mechanism................................................................................. 671 Overview................................................................................................. 673 Telescoping process...................................................................................... 674 Assignment for display................................................................................... 676 Fixed length, intermediate length, telescoping length.................................................... 677 Telescoping.............................................................................................. 678 Telescoping sequence..................................................................................... 678 Inspections prior to starting operations................................................................. 679 Switching on the telescoping mechanism................................................................... 680 Function of the control lever............................................................................ 680 Switching off the telescoping mechanism.................................................................. 682 Manual telescoping....................................................................................... 683 Checking the initial position,........................................................................... 683 Unlocking the telescoping cylinder....................................................................... 685 Extending/retracting the telescoping cylinder............................................................ 687 Lock telescoping cylinder................................................................................ 688 Unlocking the telescopic section......................................................................... 689 Telescoping the telescopic section....................................................................... 690 Locking the telescopic section........................................................................... 691 Locking the telescopic section for on-road driving....................................................... 692 Telescoping with semi-automaton.......................................................................... 692 Telescoping with pre-selection........................................................................... 694 11.5.7 High-speed mode....................................................................................... 695 Derricking gear Telescoping mechanism.................................................................... 695 Hoists................................................................................................... 695 11.5.8 Slewing gear.......................................................................................... 697 Slewing gear brake....................................................................................... 697 Switching on the slewing gear............................................................................ 698 Releasing the slewing gear brake......................................................................... 698 Applying the slewing gear brake.......................................................................... 698 Slewing.................................................................................................. 699 Permissible slewing speed................................................................................ 700 Braking the slewing movement............................................................................. 701 Slewing gear freewheel................................................................................... 701 Switching off the slewing gear........................................................................... 702 11.5.9 Switching the reduction of slewing speed on and off................................................... 703 Switching reduction off.................................................................................. 703 11.5.10 Possible movement combinations....................................................................... 704 11.6 Settings and displays for crane operation................................................................... 705 11.6.1 Inclining the crane cab............................................................................... 705 11.6.2 Idling speed, setting................................................................................. 706 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper........................................... 706 11.6.4 Limiting the power unit speeds........................................................................ 707 11.6.5 Economy mode.......................................................................................... 708 Switching on............................................................................................. 708 Ending/ switching off.................................................................................... 710 11.6.6 Switching units of measure............................................................................ 710 11.6.7 Setting the characteristic curves for the control levers.............................................. 711 11.6.8 Using the slewable spotlights......................................................................... 712 Manually swinging........................................................................................ 713 Automatic load tracking.................................................................................. 713 11.6.9 Overriding torque reduction........................................................................... 714 11.6.10 Displaying the operating hours....................................................................... 715 11.7 Working range limiter....................................................................................... 717 11.7.1 viewing current settings.............................................................................. 718 On the RCL dislay........................................................................................ 718 In the CCS Start menu.................................................................................... 719 11.7.2 Opening the working range limiter menu................................................................ 719 11.7.3 Enter limit values – for the overall height........................................................... 720 11.7.4 Enter limit values – for the working radius........................................................... 722 11.7.5 Enter limit values – for the slewing range............................................................ 724 11.7.6 Enter limit values – for the hoist rope travel........................................................ 727 11.7.7 Shutdown by working range limiter..................................................................... 729 11.8 Work break.................................................................................................. 731 11.8.1 In case of short work breaks.......................................................................... 731 11.8.2 In case of work breaks of more than 8 hours........................................................... 732 To secure the truck crane................................................................................ 732 11.9 Heating and air-conditioning system......................................................................... 733 11.9.1 Standard heating system............................................................................... 733 Switching on............................................................................................. 733 Heating.................................................................................................. 733 Air distribution......................................................................................... 734 Switching off............................................................................................ 734 11.9.2 Air-conditioning system............................................................................... 735 Notes.................................................................................................... 735 Switching on/off......................................................................................... 735 Cooling, automatic....................................................................................... 736 Cooling, maximum......................................................................................... 736 11.9.3 Auxiliary heater...................................................................................... 737 Switching on............................................................................................. 737 Setting the temperature.................................................................................. 738 Setting the heating start/ heating duration.............................................................. 738 Switching heating start on/off........................................................................... 739 11.10 CraneSTAR system........................................................................................... 740 11.10.1 Overview............................................................................................. 740 11.10.2 Position of the components........................................................................... 740 12 Rigging work...................................................................................................... 741 12.1 Rigging work checklists for crane operation with the main boom.............................................. 741 12.1.1 CHECKLIST: Rigging.................................................................................... 741 12.1.2 CHECKLIST: Unrigging.................................................................................. 747 12.2 Choice of a suitable positioning site....................................................................... 751 12.2.1 Determining the required load-bearing area............................................................ 751 12.2.2 Safe distance from slopes and pits.................................................................... 754 12.2.3 Earthing the truck crane.............................................................................. 755 12.2.4 Safe distance from overhead power lines............................................................... 756 12.3 Rigging work after driving with a dolly..................................................................... 759 12.3.1 Switching off the boom floating position.............................................................. 759 12.3.2 Switching off the slewing gear freewheel.............................................................. 760 Before slewing........................................................................................... 760 12.3.3 Switching off boom pre-tensioning..................................................................... 761 12.4 Connecting/disconnecting the hand-held control.............................................................. 763 12.5 Starting the engine for rigging............................................................................. 767 12.5.1 Starting/shutoff the engine – with the hand-held control.............................................. 767 Prerequisites............................................................................................ 767 Starting the engine...................................................................................... 768 Turning off the engine................................................................................... 768 12.5.2 Starting/shutoff the engine – from the outrigger control units........................................ 769 Prerequisites............................................................................................ 769 Starting the engine...................................................................................... 769 Switch off the engine.................................................................................... 769 12.6 Slewing range – only with the Standard slewing range type................................................... 771 12.6.1 Representation in the lifting capacity tables......................................................... 771 12.6.2 Enabled outrigger spans............................................................................... 772 12.7 Outriggers – Overview – MAXbase slewing range type.......................................................... 773 12.7.1 Definitions........................................................................................... 773 12.7.2 Representation in the lifting capacity tables......................................................... 775 12.7.3 Enabled outrigger spans............................................................................... 776 12.8 Outrigger operation......................................................................................... 781 12.8.1 CHECKLIST: Extending the outriggers................................................................... 781 12.8.2 CHECKLIST: Retracting the outriggers.................................................................. 783 12.8.3 Preparing the truck crane............................................................................. 784 Driver's cab............................................................................................. 784 Crane cab................................................................................................ 784 12.8.4 Setting the outrigger spans........................................................................... 786 For on-road driving...................................................................................... 789 12.8.5 Extending/retracting outrigger beams.................................................................. 789 From the crane cab....................................................................................... 790 From the control units................................................................................... 791 12.8.6 Moving the outrigger pads into operating/driving position............................................. 793 12.8.7 Enlarging the load-bearing area....................................................................... 795 12.8.8 Extending/retracting supporting cylinders............................................................. 796 From the control units................................................................................... 797 From the crane cab....................................................................................... 798 12.8.9 Levelling the truck crane on outriggers horizontally.................................................. 800 Inclination indicators................................................................................... 800 Prerequisites............................................................................................ 801 Manual alignment......................................................................................... 802 Automatic alignment...................................................................................... 802 12.8.10 Levelling the free-standing truck crane.............................................................. 804 12.8.11 Operating the axle raising system.................................................................... 806 12.8.12 Outrigger pressure display........................................................................... 808 12.9 Rigging/unrigging the counterweight......................................................................... 811 12.9.1 Information on rigging................................................................................ 811 When rigging............................................................................................. 811 When unrigging........................................................................................... 812 12.9.2 Counterweight sections................................................................................ 813 Version 1................................................................................................ 813 Version 2................................................................................................ 813 Version 3................................................................................................ 814 12.9.3 Identification........................................................................................ 815 12.9.4 Slinging points on the counterweight sections......................................................... 816 12.9.5 CHECKLIST: Rigging the counterweight.................................................................. 817 12.9.6 CHECKLIST: Unrigging the counterweight................................................................ 819 12.9.7 Assembling counterweight combination.................................................................. 820 Setting down the 2.3 t base plate........................................................................ 821 Setting down the top couterweight section................................................................ 821 Version 1................................................................................................ 822 Version 2................................................................................................ 830 Version 3................................................................................................ 834 12.9.8 Counterweight hoist unit.............................................................................. 842 Counterweight menu....................................................................................... 842 Extending/retracting the lifting cylinders............................................................... 843 Automatic mode rigging................................................................................... 845 Automatic mode unrigging................................................................................. 847 Cancel automatic mode.................................................................................... 848 12.9.9 Removing/installing the counterweight on the turntable................................................ 849 Removing................................................................................................. 849 Installing............................................................................................... 850 12.9.10 Setting down counterweight for driving............................................................... 851 Versions 1 and 3......................................................................................... 851 Version 2................................................................................................ 853 12.9.11 Slewing with rigged counterweight.................................................................... 853 12.10 Rigging work on the main boom.............................................................................. 855 12.10.1 Hook block on the bumper............................................................................. 855 Picking up the hook block................................................................................ 855 Attaching the hook block................................................................................. 856 12.10.2 Hook block on a separate vehicle..................................................................... 857 Picking up the hook block................................................................................ 858 Setting down the hook block.............................................................................. 858 12.10.3 Hook block, separable................................................................................ 860 Rigging for on- road driving............................................................................. 860 Rigging for crane operation.............................................................................. 861 12.10.4 Hook block with ballast plates....................................................................... 862 Removing................................................................................................. 862 Installing............................................................................................... 863 Information on crane operation........................................................................... 863 12.10.5 Reeving and unreeving the hoist rope................................................................. 864 Version A................................................................................................ 864 Version B................................................................................................ 865 Reeving the hoist rope................................................................................... 867 Unreeving hoist rope..................................................................................... 871 12.10.6 Possible reevings on the main boom................................................................... 872 With 6 head sheaves...................................................................................... 872 With 8 head sheaves...................................................................................... 875 With 9 head sheaves...................................................................................... 878 12.10.7 Installing/removing the lifting limit switch......................................................... 879 Installing the lifting limit switch...................................................................... 879 Removing the lifting limit switch........................................................................ 882 12.10.8 Locking/unlocking the lifting limit switch........................................................... 884 Locking.................................................................................................. 884 Removing the lock........................................................................................ 884 12.10.9 Anemometer and air traffic control light............................................................. 885 Installing............................................................................................... 885 Switching on/off......................................................................................... 886 Removing................................................................................................. 887 12.11 Other rigging work......................................................................................... 889 12.11.1 Railings on the turntable............................................................................ 889 12.11.2 Folding the mirrors in and out, and adjusting them................................................... 890 12.11.3 Slinging points for personal protective equipment.................................................... 891 12.11.4 Cameras for crane operation.......................................................................... 892 Camera on main boom...................................................................................... 892 Camera on the hoists..................................................................................... 895 Camera on the driver's cab............................................................................... 895 Operating the camera..................................................................................... 896 12.11.5 Step at the crane cab................................................................................ 897 13 Driving with a rigged truck crane................................................................................. 899 13.1 Route....................................................................................................... 899 13.2 Permissible rigging modes and axle loads.................................................................... 900 Axle load table.............................................................................................. 900 13.2.1 To drive without a load............................................................................... 903 13.2.2 To drive with a load.................................................................................. 903 13.2.3 Axle loads............................................................................................ 904 13.3 Before driving the rigged truck crane....................................................................... 905 13.3.1 Check the tyre pressures and wind speed............................................................... 905 13.3.2 Secure the superstructure against slewing............................................................. 905 13.3.3 Putting the truck crane on the wheels – with Raise axle function...................................... 906 13.3.4 Putting the truck crane on the wheels – with the outriggers........................................... 908 13.4 Driving from the driver's cab............................................................................... 911 13.4.1 Preparing to drive.................................................................................... 911 Transmission............................................................................................. 911 Switching on separate steering........................................................................... 911 Connections.............................................................................................. 911 13.4.2 Whilst driving........................................................................................ 912 13.4.3 After driving......................................................................................... 913 13.5 Driving from the crane cab.................................................................................. 915 13.5.1 Preparing to drive.................................................................................... 916 13.5.2 Opening/closing the driving menu...................................................................... 917 Opening the menu......................................................................................... 917 Selecting the operating mode............................................................................. 917 Crane's hydraulic system Driving mode.................................................................... 919 Closing menu............................................................................................. 919 13.5.3 Steering.............................................................................................. 920 Switching on............................................................................................. 920 Display and steering direction........................................................................... 920 Switching the steering direction......................................................................... 921 Displays when steering................................................................................... 921 Separate steering........................................................................................ 922 Normal steering mode..................................................................................... 925 13.5.4 Operating the transmission............................................................................ 926 Selecting the transmission mode.......................................................................... 926 13.5.5 Whilst driving........................................................................................ 927 DM and RM transmission mode.............................................................................. 927 Transmission mode D...................................................................................... 927 Warning messages......................................................................................... 927 13.5.6 Possible connections.................................................................................. 928 Longitudinal/ transverse differential locks.............................................................. 928 13.5.7 After driving......................................................................................... 930 14 Malfunctions during crane operation............................................................................... 931 14.1 Emergency stop switch....................................................................................... 931 14.2 What to do when malfunctions occur during crane operation................................................... 932 The load can be set down..................................................................................... 932 Load cannot be set down...................................................................................... 932 14.3 Warning and error messages.................................................................................. 933 Program version.............................................................................................. 933 14.3.1 Warning messages on the CCS display................................................................... 933 Meaning of the symbols................................................................................... 934 14.3.2 Error messages on the CCS display..................................................................... 938 14.3.3 Warning messages on the RCL display................................................................... 940 14.4 Troubleshooting............................................................................................. 945 14.4.1 Malfunctions on the engine............................................................................ 945 14.4.2 Malfunctions on the main hoist/auxiliary hoist........................................................ 945 14.4.3 Malfunctions in the hoist cameras..................................................................... 947 14.4.4 Malfunctions in the main boom camera.................................................................. 947 14.4.5 Malfunctions on the derricking gear................................................................... 948 14.4.6 Malfunctions in the telescoping mechanism............................................................. 949 14.4.7 Malfunctions on the slewing gear...................................................................... 950 14.4.8 Malfunctions on the counterweight hoist unit.......................................................... 952 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler............................................. 952 14.4.10 Malfunctions when operating with the hand-held control............................................... 953 14.4.11 Malfunctions when inclining the crane cab............................................................ 953 14.4.12 Malfunctions when raising the axles.................................................................. 953 14.4.13 Malfunctions of the outriggers....................................................................... 954 14.4.14 Malfunctions on the turntable lock................................................................... 954 14.4.15 Malfunctions on the CCS/RCL control units............................................................ 955 14.4.16 Malfunctions when driving from the crane cab......................................................... 955 14.4.17 Malfunctions on the CraneSTAR system................................................................. 956 14.5 Emergency operations and programs........................................................................... 959 14.5.1 Mechanical emergency activation for retracting........................................................ 960 Prior to the emergency operation, check.................................................................. 960 Procedure................................................................................................ 960 Mechanical emergency activation.......................................................................... 961 14.5.2 Telescoping emergency program......................................................................... 963 Telescoping emergency program menu....................................................................... 963 Determining the type of error............................................................................ 964 Error at the length indicator............................................................................ 965 Tables for approaching the locking points................................................................ 969 14.5.3 Entering the current telescoping...................................................................... 971 14.5.4 Emergency operation with the hand-held control........................................................ 973 To pre-select a power unit............................................................................... 974 Operating a power unit................................................................................... 974 Stopping movements....................................................................................... 975 Stopping movements in emergencies........................................................................ 976 Switch off the engine.................................................................................... 976 14.5.5 Notes on slewing in emergency operation............................................................... 976 For the Standard slewing range type...................................................................... 976 For the MAXbase slewing range type....................................................................... 978 14.5.6 Rotate for overridden slewing gear shutdown........................................................... 979 14.6 Hydraulic emergency operation with the hand pump............................................................ 981 14.6.1 Operating principle................................................................................... 981 14.6.2 Switching over the crane's hydraulic system........................................................... 982 14.6.3 Establishing the hydraulic circuits required.......................................................... 983 Releasing/ securing valves............................................................................... 983 Switching over valves.................................................................................... 984 For lowering............................................................................................. 985 14.6.4 Performing emergency activation....................................................................... 986 14.6.5 After emergency activation............................................................................ 987 14.7 Hydraulic emergency operation acc. to BGR 159............................................................... 989 14.7.1 Applications and function............................................................................. 989 14.7.2 CHECKLIST: Emergency operation........................................................................ 991 14.7.3 CHECKLIST: After emergency operation.................................................................. 992 14.7.4 Connecting/removing transformer – for self-sufficiency................................................ 993 Connecting............................................................................................... 993 Removing................................................................................................. 994 14.7.5 Switching emergency operation on/off.................................................................. 995 14.7.6 Connecting/removing transformer – for external energy source.......................................... 996 14.7.7 Establishing the required hydraulic circuits.......................................................... 997 Valves at the control panel.............................................................................. 997 For lifting/ lowering.................................................................................... 999 For slewing..............................................................................................1000 14.7.8 Performing emergency operation........................................................................1001 Slewing..................................................................................................1001 Derricking...............................................................................................1002 Lifting/lowering.........................................................................................1002 14.7.9 Emergency supply of another crane.....................................................................1003 For emergency supply.....................................................................................1003 After emergency supply...................................................................................1003 14.8 Fuses in the crane cab......................................................................................1005 Information on changing fuses................................................................................1005 Index....................................................................................................................1011 A....................................................................................................................1013 B....................................................................................................................1013 C....................................................................................................................1014 D....................................................................................................................1016 E....................................................................................................................1018 F....................................................................................................................1020 H....................................................................................................................1020 I....................................................................................................................1021 L....................................................................................................................1021 M....................................................................................................................1022 O....................................................................................................................1023 P....................................................................................................................1025 R....................................................................................................................1025 S....................................................................................................................1026 T....................................................................................................................1027 V....................................................................................................................1029 W....................................................................................................................1029
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