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Grove Crane GMK 5150 Operating Manual – PDF DOWNLOAD
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Description
Grove Crane GMK 5150 Operating Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5150 Operating Manual – PDF DOWNLOAD
Language : English
Pages : 1040
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 5150 Operating Manual – 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 – PDF DOWNLOAD
Operating manual............................................................................................................. 1 Additional pages......................................................................................................... 3 Outrigger spans...................................................................................................... 3 Driving from the crane cab........................................................................................... 5 Telescoping emergency programe....................................................................................... 7 Crane cab heating and air-conditioning system........................................................................ 13 Operation from the driver's cab.................................................................................. 13 Hook blocks.......................................................................................................... 9 Change / correction to the technical data........................................................................ 9 Revision..................................................................................................... 9 Correction to thetechnical data.............................................................................. 10 Table of contens......................................................................................................... 17 General.................................................................................................................. 47 1 Overview........................................................................................................... 47 1.1 General instructions......................................................................................... 47 1.2 Accidents.................................................................................................... 47 1.3 Branch offices............................................................................................... 49 1.3.1 Manitowoc Crane Care................................................................................... 49 1.3.2 Dealer list............................................................................................ 49 1.4 Warranty specifications...................................................................................... 49 1.5 Terms used................................................................................................... 50 1.6 Technical data............................................................................................... 53 1.6.1 Maximum lifting capacity (ASME B 30.5)................................................................. 53 1.6.2 Dimensions and weights of the truck crane, axle loads.................................................. 54 Dimensions............................................................................................... 55 Weight and axle loads.................................................................................... 55 1.6.3 Dimensions and weights of removable parts.............................................................. 56 Spare wheel.............................................................................................. 56 Outrigger................................................................................................ 56 Main boom................................................................................................ 56 Hook blocks and hook tackle.............................................................................. 57 Auxiliary hoist.......................................................................................... 59 Counterweight parts...................................................................................... 60 1.6.4 Carrier................................................................................................ 63 Engine................................................................................................... 63 Transmission............................................................................................. 63 Transfer case............................................................................................ 63 Axle lines............................................................................................... 63 Steering................................................................................................. 64 Tyres.................................................................................................... 64 Turning turning radii.................................................................................... 64 Outrigger................................................................................................ 65 Electrical system........................................................................................ 66 Tool..................................................................................................... 66 Towing couplings......................................................................................... 66 Driving speeds........................................................................................... 66 Climbing ability......................................................................................... 66 1.6.5 Superstructure......................................................................................... 67 Main hoist............................................................................................... 67 Auxiliary hoist.......................................................................................... 67 Slewing gears............................................................................................ 67 Derricking gear.......................................................................................... 67 Main boom................................................................................................ 68 Lattice extension........................................................................................ 68 Operating speeds......................................................................................... 68 1.7 Documentation supplied....................................................................................... 69 1.7.1 Questions on documentation............................................................................. 70 1.8 Notes on the operating manual................................................................................ 71 1.8.1 What do the symbols used mean?......................................................................... 71 1.8.2 How is the operating manual structured?................................................................ 73 Division................................................................................................. 73 Structure of the chapters................................................................................ 73 Structure of the pages................................................................................... 74 1.8.3 How do I find the information I need?.................................................................. 75 Cross-references example................................................................................. 76 1.8.4 What information is available for operations planning?................................................. 78 1.9 Conversion table for US measuring units...................................................................... 79 1.10 Training - Information...................................................................................... 81 1.11 Identification.............................................................................................. 82 1.12 EC Declaration of Conformity................................................................................ 84 2 Basic safety instructions.......................................................................................... 85 2.1 Intended use................................................................................................. 85 2.1.1 Improper use........................................................................................... 86 2.2 Organisational measures...................................................................................... 87 2.3 Personnel qualifications..................................................................................... 89 2.4 Safety instructions for driving the truck crane.............................................................. 90 2.5 Safety instructions for crane operation...................................................................... 91 2.6 Instructions on transporting persons......................................................................... 94 Equipment for lifting persons................................................................................ 94 Personnel.................................................................................................... 94 Operation.................................................................................................... 95 Truck crane.................................................................................................. 96 Driving.................................................................................................................. 97 3 Operating elements for driving..................................................................................... 97 3.1 Overview of the operating elements........................................................................... 97 3.1.1 On the outside of the truck crane...................................................................... 98 3.1.2 Driver's cab........................................................................................... 102 Front overview........................................................................................... 102 Rear overview............................................................................................ 104 Behind the cover......................................................................................... 105 3.1.3 Steering column/steering wheel......................................................................... 106 3.1.4 Instrument panel....................................................................................... 107 Left/right............................................................................................... 107 Middle................................................................................................... 108 3.1.5 Transmission operating elements........................................................................ 110 3.1.6 On-board computer...................................................................................... 111 3.1.7 Tachograph............................................................................................. 112 3.1.8 Heating and air-conditioning system.................................................................... 113 Standard................................................................................................. 113 Auxiliary water heating system........................................................................... 114 Auxiliary air heater..................................................................................... 115 3.1.9 CCS control unit....................................................................................... 117 3.1.10 CCS – menu-dependent displays......................................................................... 118 3.1.11 CCS – Start menu...................................................................................... 119 3.1.12 CCS – Overview menu groups............................................................................ 120 3.1.13 Carrier menu group.................................................................................... 122 Suspension/level adjustment menu......................................................................... 123 Driving menu............................................................................................. 124 3.1.14 Settings menu group................................................................................... 125 Set display brightness and date/time menu................................................................ 126 Switch units menu........................................................................................ 127 3.1.15 Menu group Information................................................................................ 128 Operating hours menu..................................................................................... 129 Engine/transmission error menu........................................................................... 130 Crane operation error menu............................................................................... 131 3.1.16 Various controls menu group........................................................................... 132 3.1.17 Emergency operations menu group....................................................................... 133 3.1.18 Outrigger control units............................................................................... 134 3.2 Short description of the operating elements.................................................................. 135 3.2.1 Definition of information relating to directions of movement........................................... 136 Basic rule............................................................................................... 136 3.2.2 General rules for buttons and symbols on the display................................................... 137 3.2.3 Engine................................................................................................. 138 Steering column.......................................................................................... 138 On the steering wheel.................................................................................... 138 Instrument panel......................................................................................... 139 3.2.4 AdBlue system.......................................................................................... 140 Instrument panel......................................................................................... 140 CCS display.............................................................................................. 141 3.2.5 Battery master switch.................................................................................. 141 3.2.6 Electrical system...................................................................................... 142 3.2.7 Crane control CCS...................................................................................... 143 3.2.8 Transmission........................................................................................... 145 Transmission control unit................................................................................ 145 Display, driving mode.................................................................................... 147 3.2.9 Reverse camera......................................................................................... 148 3.2.10 BirdView system 270°.................................................................................. 149 3.2.11 Transfer case......................................................................................... 151 3.2.12 Final drive........................................................................................... 153 3.2.13 Brakes................................................................................................ 154 Service brake............................................................................................ 154 Additional brakes........................................................................................ 154 Parking brake............................................................................................ 155 3.2.14 Steering/separate steering............................................................................ 156 Instrument panel......................................................................................... 156 CCS display.............................................................................................. 158 3.2.15 Suspension............................................................................................ 160 CCS display.............................................................................................. 160 3.2.16 Lighting/windscreen wipers/horn....................................................................... 161 Steering column.......................................................................................... 161 Steering wheel........................................................................................... 161 Instrument panel......................................................................................... 161 CCS display.............................................................................................. 163 Roof..................................................................................................... 163 3.2.17 Level adjustment system............................................................................... 164 3.2.18 Tachograph/speedometer................................................................................ 166 Tachograph............................................................................................... 166 Cover.................................................................................................... 166 Speedometer.............................................................................................. 166 3.2.19 Diagnostics........................................................................................... 167 3.2.20 Push-up roof.......................................................................................... 167 3.2.21 On-board computer..................................................................................... 168 3.2.22 Front flap............................................................................................ 169 3.2.23 Windows and doors..................................................................................... 170 Window winder............................................................................................ 170 Doors.................................................................................................... 171 3.2.24 Access ladders and ladders............................................................................ 173 4 Starting the engine for driving / switching it off................................................................. 177 4.1 Starting the engine from the driver's cab.................................................................... 177 4.1.1 CHECKLIST: Starting the engine......................................................................... 177 4.1.2 CHECKLIST: At low temperatures......................................................................... 180 4.1.3 Filling up............................................................................................. 181 Fuel tank................................................................................................ 181 AdBlue tank.............................................................................................. 183 4.1.4 Checks before starting the engine...................................................................... 184 At the hydraulic tank.................................................................................... 184 Battery master switch.................................................................................... 185 Checking the hand-held control........................................................................... 185 4.1.5 Switch the ignition on................................................................................. 185 4.1.6 Lamp test/equalisation of the switching states......................................................... 186 Lamp test................................................................................................ 186 Switching state alignment................................................................................ 186 4.1.7 Display – setting the brightness....................................................................... 187 4.1.8 Starting the engine.................................................................................... 189 4.1.9 Checks after starting the engine....................................................................... 191 Start menu and on-board computer......................................................................... 191 Instrument panel......................................................................................... 192 4.1.10 Setting the idling speed.............................................................................. 193 4.2 Switch off the engine........................................................................................ 194 4.2.1 At the ignition lock and with the outrigger control units.............................................. 194 After switching off...................................................................................... 194 4.2.2 Using the emergency stop switches...................................................................... 195 Resetting the emergency stop switch...................................................................... 195 4.3 Air intake inhibitor......................................................................................... 196 Opening the air intake inhibitor............................................................................. 196 5 Driving............................................................................................................ 197 5.1 Before driving............................................................................................... 197 5.1.1 CHECKLIST: checks before on-road driving............................................................... 197 5.1.2 Check the condition of the truck crane................................................................. 203 Electrical system........................................................................................ 203 Adjusting the mirrors.................................................................................... 203 Warning plates for vehicle width......................................................................... 205 Checking the vehicle height.............................................................................. 205 Supply pressure.......................................................................................... 206 Parking brake............................................................................................ 207 Third brake light........................................................................................ 208 5.1.3 Adjusting the seat and the steering column............................................................. 209 Adjusting the driver's seat.............................................................................. 209 Adjusting the passenger seat............................................................................. 210 Adjusting the steering column............................................................................ 211 5.1.4 Switching the suspension on/off........................................................................ 212 Open menu................................................................................................ 212 Switching the suspension on.............................................................................. 213 Switching the suspension off............................................................................. 213 5.1.5 Setting the tachograph................................................................................. 214 Prerequisites............................................................................................ 214 In the event of malfunctions............................................................................. 214 Setting the tachograph................................................................................... 215 5.1.6 Setting the time....................................................................................... 219 5.1.7 Displaying and resetting operating hours............................................................... 220 5.2 Operating the transmission................................................................................... 221 5.2.1 Switching on........................................................................................... 221 5.2.2 Switching the transmission to the neutral position..................................................... 222 5.2.3 Selecting the direction of travel and starting gear.................................................... 223 Selecting the driving direction.......................................................................... 223 Selecting the starting gear.............................................................................. 224 5.2.4 Changing the operating mode............................................................................ 225 Changing to automatic mode............................................................................... 225 Change to manual mode.................................................................................... 225 5.2.5 Starting............................................................................................... 226 5.2.6 Driving and changing gears............................................................................. 227 In automatic operating mode.............................................................................. 227 In manual operating mode................................................................................. 228 5.2.7 Changing the driving direction......................................................................... 229 5.2.8 Stopping............................................................................................... 229 Stopping for longer periods.............................................................................. 229 5.2.9 On the roller type dynamometer......................................................................... 230 5.2.10 Preheating transmission............................................................................... 230 5.3 Driving the truck crane and switching it off................................................................. 231 5.3.1 Checks whilst driving.................................................................................. 231 Brakes................................................................................................... 231 ABS system............................................................................................... 231 Steering................................................................................................. 232 Warning messages......................................................................................... 232 Monitoring elements...................................................................................... 233 5.3.2 Cruise control......................................................................................... 234 Switching on............................................................................................. 234 Switching off............................................................................................ 235 5.3.3 Temposet............................................................................................... 236 Switching on............................................................................................. 236 Switching off............................................................................................ 236 5.3.4 Driving downhill....................................................................................... 237 Starting................................................................................................. 237 Checks when driving downhill............................................................................. 238 Downshifting............................................................................................. 238 Additional brakes........................................................................................ 239 5.3.5 Driving uphill......................................................................................... 240 Starting................................................................................................. 240 Driving.................................................................................................. 240 5.3.6 Overriding torque reduction............................................................................ 241 5.3.7 Switching the truck crane off.......................................................................... 242 Secure it against rolling away........................................................................... 242 When stationary for more than 8 hours.................................................................... 243 5.3.8 Fold-up berth.......................................................................................... 244 5.4 Off-road driving............................................................................................. 245 Adjustments to the transmission.............................................................................. 245 Connections.................................................................................................. 245 Changing the vehicle level................................................................................... 245 Rocking the vehicle free and towing.......................................................................... 245 5.4.1 Transfer case – switching the off-road gear on/off..................................................... 246 5.4.2 Longitudinal and transverse differential locks......................................................... 247 5.4.3 Operating the level adjustment system.................................................................. 249 Open menu................................................................................................ 249 Setting the on-road level................................................................................ 250 Pre-selecting suspension struts.......................................................................... 250 Changing the vehicle level............................................................................... 251 Viewing the current inclination.......................................................................... 252 Exiting the menu......................................................................................... 252 5.4.4 Freeing truck crane stuck in terrain................................................................... 253 Rocking the truck crane free............................................................................. 253 Towing free forwards..................................................................................... 254 Towing free to the rear.................................................................................. 254 5.5 Separate steering............................................................................................ 255 5.5.1 Switching to separate steering......................................................................... 256 5.5.2 Switching to normal steering mode...................................................................... 259 5.5.3 Switching units of measure............................................................................. 260 5.6 Heating and air-conditioning system.......................................................................... 261 5.6.1 Standard heating system................................................................................ 261 Switching on............................................................................................. 261 Heating.................................................................................................. 261 Air distribution......................................................................................... 262 Examples................................................................................................. 263 Switching off............................................................................................ 263 5.6.2 Air-conditioning system................................................................................ 264 Notes.................................................................................................... 264 Switching on/off......................................................................................... 264 Cooling.................................................................................................. 265 Drying................................................................................................... 265 5.6.3 Auxiliary water heating system......................................................................... 266 Preheating the engine.................................................................................... 266 Preheating the driver's cab.............................................................................. 267 Switching on............................................................................................. 267 Setting the date and time................................................................................ 269 Storing the heating start................................................................................ 270 5.6.4 Auxiliary air heater................................................................................... 272 Switching on............................................................................................. 272 Setting the heating level................................................................................ 273 Setting the day and time................................................................................. 274 Setting the preselection time............................................................................ 274 Preselection times Delete................................................................................ 276 Switching off............................................................................................ 276 5.7 Radio........................................................................................................ 276 5.8 Towing a trailer............................................................................................. 277 Effects on the axle loads.................................................................................... 277 Coupling the trailer......................................................................................... 278 Connecting the supply lines.................................................................................. 279 Removing supply lines........................................................................................ 280 Uncoupling the trailer....................................................................................... 280 Checking the braking force................................................................................... 282 6 Driving modes and rigging for on-road driving...................................................................... 283 6.1 Driving modes................................................................................................ 283 Information about the axle loads............................................................................. 283 6.1.1 How to use the tables.................................................................................. 284 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs)..................................................... 285 Tyres 385/95 R25......................................................................................... 285 Tyres 445/95 R25......................................................................................... 286 Tyres 525/80 R25......................................................................................... 287 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs)................................... 288 6.2 Weighing the truck crane..................................................................................... 289 Axle groups.................................................................................................. 290 Weighing procedure........................................................................................... 291 Evaluation................................................................................................... 292 6.3 Rigging work for driving with a dolly........................................................................ 293 6.3.1 Switching on the slewing gear freewheel................................................................ 294 6.3.2 Switching on the boom floating position................................................................ 295 6.3.3 Switching on boom pre-tensioning....................................................................... 296 6.3.4 Raising/lowering the 3rd axle line for dolly operation................................................. 297 6.4 Rigging the main boom........................................................................................ 299 Additional equipment required................................................................................ 299 6.4.1 CHECKLIST: Removing the main boom...................................................................... 300 Prerequisites............................................................................................ 300 Checklist................................................................................................ 300 6.4.2 CHECKLIST: Mounting the main boom...................................................................... 303 Prerequisites............................................................................................ 303 Checklist................................................................................................ 303 6.4.3 Disconnecting/connecting hydraulics/electrical......................................................... 306 6.4.4 Derricking cylinder support............................................................................ 308 6.4.5 Slinging the main boom................................................................................. 308 Marking.................................................................................................. 308 Attach lifting gear...................................................................................... 309 Removing the sling gear.................................................................................. 310 6.4.6 Switching the pressure relief on/off................................................................... 311 6.4.7 Retracting/fitting the derricking cylinder head pin.................................................... 312 Operating the lifting device............................................................................. 312 Pulling the derricking cylinder head axle................................................................ 312 Fitting the derricking cylinder head axle................................................................ 313 6.4.8 Extending/retracting the boom pivot pin................................................................ 314 Pulling out the pivot pin................................................................................ 314 Pushing the pivot pin in................................................................................. 316 6.4.9 Transporting the main boom............................................................................. 317 6.4.10 Securing/releasing the derricking cylinder............................................................ 317 6.4.11 Aligning the connecting points........................................................................ 318 6.4.12 Inspections after main boom mounting.................................................................. 319 6.5 Rigging the auxiliary hoist.................................................................................. 321 6.5.1 Slinging the auxiliary hoist........................................................................... 321 6.5.2 CHECKLIST: Installing the auxiliary hoist.............................................................. 322 6.5.3 CHECKLIST: Removing the auxiliary hoist................................................................ 323 6.5.4 Making/breaking the connection between the auxiliary hoist and the turntable........................... 324 6.5.5 Establishing/disconnecting the hydraulic connections................................................... 325 6.5.6 Disconnecting/establishing the electrical connection................................................... 326 6.5.7 Making/breaking the connection to the central lubrication.............................................. 327 6.5.8 Transporting the auxiliary hoist....................................................................... 328 6.5.9 Check that the auxiliary hoist is functioning properly................................................. 329 Slewing direction........................................................................................ 329 Slewing indicator........................................................................................ 329 6.5.10 Rigging aid for the hoist rope........................................................................ 330 6.6 Installing/removing the outrigger beams...................................................................... 333 6.6.1 CHECKLIST: Removing the outrigger beams................................................................ 334 6.6.2 CHECKLIST: Installing the outrigger beams.............................................................. 336 6.6.3 Centre of gravity data................................................................................. 338 6.6.4 Preparations – for removal............................................................................. 338 6.6.5 Preparations – on the truck crane...................................................................... 339 Prerequisites............................................................................................ 339 6.6.6 Removing/attaching outrigger pads...................................................................... 340 Removing the outrigger pads.............................................................................. 340 Attaching the outrigger pads............................................................................. 341 6.6.7 Disconnecting/establishing hydraulic connection........................................................ 342 6.6.8 Disconnecting/establishing the electrical connection................................................... 343 6.6.9 Unscrewing/screwing in the spacers..................................................................... 344 Unscrewing............................................................................................... 344 Screwing in.............................................................................................. 345 6.6.10 Disconnecting/establishing the connections to the supporting box...................................... 346 6.6.11 Pulling out/Inserting the outrigger beam.............................................................. 346 Extending the outrigger beam............................................................................. 346 Inserting the outrigger beam............................................................................. 348 6.6.12 Transporting the outrigger beams...................................................................... 350 6.6.13 Note on error messages with removed outrigger beams................................................... 350 7 Transport.......................................................................................................... 351 7.1 Transport with transport vehicle............................................................................. 351 7.1.1 CHECKLIST: Checks before transport..................................................................... 352 7.1.2 Drive the truck crane on to the transport vehicle...................................................... 354 Driving on............................................................................................... 355 Lashing.................................................................................................. 355 7.2 Transport by ship............................................................................................ 356 8 Malfunctions in driving mode....................................................................................... 357 8.1 Emergency stop switch........................................................................................ 357 8.2 Procedure during malfunctions................................................................................ 358 8.2.1 What to do when a malfunction occurs in road traffic................................................... 358 8.2.2 Procedure during engine malfunctions................................................................... 359 8.2.3 Procedure during transmission malfunctions............................................................. 360 8.3 Warning and error messages................................................................................... 361 8.3.1 Warning or malfunction messages on the instrument panel................................................ 361 Meaning of the lamps..................................................................................... 361 8.3.2 Warning and malfunction messages on the on-board computer display...................................... 365 Messages................................................................................................. 365 Symbols.................................................................................................. 366 8.3.3 Warning messages on the CCS display.................................................................... 369 Symbols in the display area.............................................................................. 369 8.3.4 Error messages on the CCS display...................................................................... 373 Exiting the menu......................................................................................... 374 Special error messages................................................................................... 374 8.4 Troubleshooting.............................................................................................. 375 8.4.1 Malfunctions on the engine............................................................................. 375 When operating with the dual tank........................................................................ 377 8.4.2 Faults on the Adblue system............................................................................ 377 8.4.3 Differential lock malfunctions......................................................................... 378 8.4.4 Transfer case malfunctions............................................................................. 378 8.4.5 Malfunctions in the transmission....................................................................... 379 8.4.6 Malfunctions of the steering........................................................................... 380 8.4.7 Malfunctions of the service brake...................................................................... 381 8.4.8 Malfunctions on the suspension......................................................................... 381 8.4.9 Malfunctions of the level adjustment system............................................................ 382 8.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler............................................. 382 8.5 Emergency operation and breakdown assistance................................................................. 383 8.5.1 Starting the truck crane externally.................................................................... 383 8.5.2 Battery charger........................................................................................ 384 Prerequisites............................................................................................ 384 8.5.3 Towing the truck crane................................................................................. 385 In the case of engine/transmission damage................................................................ 385 Longer towing distances.................................................................................. 388 Tow starting............................................................................................. 388 8.5.4 Wheel change........................................................................................... 389 Removing a damaged wheel................................................................................. 390 On the spare wheel holder................................................................................ 390 Mounting a wheel......................................................................................... 392 8.5.5 Inflating the tyres yourself........................................................................... 393 Connecting the filling hose.............................................................................. 393 Inflating the tyres...................................................................................... 394 Remove the filling hose.................................................................................. 394 8.5.6 Emergency operation, steering 3rd and 4th axle lines................................................... 395 Performing emergency operation........................................................................... 396 After emergency operation................................................................................ 398 8.6 Tilting/lowering the driver's cab............................................................................ 399 8.6.1 Prerequisites and information on tilting............................................................... 399 8.6.2 Tilting and lowering the driver's cab.................................................................. 400 Operating the hand pump.................................................................................. 400 Tilting the driver's cab................................................................................. 401 Lowering the driver's cab................................................................................ 402 8.7 Fuses on the carrier......................................................................................... 405 Information on changing fuses................................................................................ 405 8.7.1 Fuses in the driver's cab.............................................................................. 406 8.7.2 Fuses in the battery box............................................................................... 412 Crane Operation.......................................................................................................... 413 9 Operating elements for crane operation............................................................................. 413 9.1 Overview of the operating elements........................................................................... 413 9.1.1 Exterior of the truck crane............................................................................ 414 9.1.2 Crane cab.............................................................................................. 418 Side panel............................................................................................... 420 Crane cab, rear.......................................................................................... 422 9.1.3 Control panels......................................................................................... 424 Left..................................................................................................... 424 Right.................................................................................................... 425 9.1.4 Control lever assignment............................................................................... 426 Version 1................................................................................................ 426 Version 2................................................................................................ 427 9.1.5 CCS control unit....................................................................................... 428 9.1.6 Menu-independent displays.............................................................................. 430 9.1.7 CCS – Start menu....................................................................................... 431 RCL display.............................................................................................. 432 Display Slewing ranges/working radii..................................................................... 433 9.1.8 CCS – Overview menu groups............................................................................. 434 9.1.9 Superstructure menu group.............................................................................. 438 Superstructure lock sub-menu............................................................................. 439 Counterweight menu....................................................................................... 440 9.1.10 Menu group outrigger/driving.......................................................................... 441 Outrigger menu........................................................................................... 442 Outrigger cylinders menu................................................................................. 444 Driving menu............................................................................................. 446 9.1.11 RCL/Telescoping menu group............................................................................ 449 Menu enter rigging mode/ telescope....................................................................... 450 Pre-selection telescoping menu........................................................................... 454 Lifting capacity tables menu............................................................................. 456 Telescoping semi- automation menu........................................................................ 457 Manual telescoping menu.................................................................................. 458 9.1.12 Working range limiter menu group...................................................................... 459 Overall height menu...................................................................................... 460 Working radius menu...................................................................................... 461 Slewing angle menu....................................................................................... 462 Hoist rope travel limitation menu........................................................................ 463 9.1.13 Information 1 menu group.............................................................................. 464 Hydraulic pressure and fuel consumption menu............................................................. 465 9.1.14 Heating/Engine/Additional equipment menu group........................................................ 466 Economy menu............................................................................................. 467 Remote control menu...................................................................................... 468 Heating/air-conditioning menu............................................................................ 469 Spotlights menu.......................................................................................... 470 9.1.15 Telescoping emergency program menu group.............................................................. 471 Telescoping emergency program menu....................................................................... 472 Unknown telescoping menu................................................................................. 474 9.1.16 Menu group, settings.................................................................................. 475 Crane cab menu........................................................................................... 476 Set display brightness and date/ time menu............................................................... 477 Switch units menu........................................................................................ 478 Set control lever characteristic curve menu.............................................................. 479 Power unit speeds menu................................................................................... 480 9.1.17 Information 2 menu group.............................................................................. 481 Operating hours menu..................................................................................... 482 Engine/transmission error menu........................................................................... 483 Crane operation error menu............................................................................... 484 Program version menu..................................................................................... 485 9.1.18 Various controls...................................................................................... 487 9.1.19 RCL control unit...................................................................................... 488 9.1.20 Menu-independent displays............................................................................. 489 9.1.21 RCL – menus........................................................................................... 490 Monitoring menu.......................................................................................... 490 Lifting capacity tables menu............................................................................. 492 Datalogger menu.......................................................................................... 493 9.1.22 Hand-held control..................................................................................... 495 9.1.23 Outriggers control units.............................................................................. 497 Menu-independent buttons................................................................................. 497 Outrigger menu........................................................................................... 498 Raise axle menu.......................................................................................... 500 9.2 Short description of the operating elements.................................................................. 501 9.2.1 Definition of information relating to directions of movement........................................... 501 Basic rule............................................................................................... 501 9.2.2 General rules for buttons and symbols on the display................................................... 502 9.2.3 Engine................................................................................................. 503 Side panel............................................................................................... 503 Left control lever....................................................................................... 503 Economy mode menu........................................................................................ 504 9.2.4 AdBlue system.......................................................................................... 504 CCS display.............................................................................................. 504 9.2.5 Seat contact switch and dead man's switch.............................................................. 506 9.2.6 Crane control CCS...................................................................................... 507 9.2.7 Outrigger – crane cab.................................................................................. 512 Control panels........................................................................................... 512 CCS display.............................................................................................. 513 9.2.8 Outrigger control units................................................................................ 515 General information...................................................................................... 515 Outrigger menu........................................................................................... 516 9.2.9 Raise axle............................................................................................. 518 9.2.10 Inclination indicators................................................................................ 520 9.2.11 Outrigger pressure displays........................................................................... 521 Outrigger menu........................................................................................... 521 Outriggers control units................................................................................. 521 9.2.12 Anemometer displays................................................................................... 521 9.2.13 Counterweight menu.................................................................................... 522 9.2.14 Main hoist............................................................................................ 526 Control panels........................................................................................... 526 CCS display.............................................................................................. 526 9.2.15 Auxiliary hoist....................................................................................... 528 Control panels........................................................................................... 528 CCS display.............................................................................................. 529 9.2.16 Slewing gear.......................................................................................... 530 Control panels........................................................................................... 530 CCS display.............................................................................................. 531 9.2.17 Derricking gear....................................................................................... 532 Control panels........................................................................................... 532 CCS display.............................................................................................. 533 Side panel............................................................................................... 533 9.2.18 Telescoping mechanism................................................................................. 534 Control panels........................................................................................... 534 CCS display.............................................................................................. 535 Telescoping semi- automation menu........................................................................ 535 Manual telescoping menu.................................................................................. 537 9.2.19 Hydraulic system...................................................................................... 540 9.2.20 Superstructure lock/house lock menu................................................................... 541 Superstructure lock...................................................................................... 541 Houselock................................................................................................ 543 9.2.21 Remote control........................................................................................ 544 9.2.22 Rated capacity limiter (RCL).......................................................................... 545 CCS display.............................................................................................. 545 RCL display.............................................................................................. 554 RCL override – version A................................................................................. 555 RCL override – version B................................................................................. 556 9.2.23 Electrical system..................................................................................... 557 9.2.24 Lighting, windscreen wiper/washing system............................................................. 558 Lighting................................................................................................. 558 Windscreen wiper/washing system.......................................................................... 560 Horn..................................................................................................... 561 9.2.25 Hand-held control..................................................................................... 562 Sockets for hand- held control........................................................................... 562 Engine control panel..................................................................................... 563 Horn..................................................................................................... 563 9.2.26 Windows and doors..................................................................................... 566 window................................................................................................... 566 rear window.............................................................................................. 566 Crane cab door........................................................................................... 567 9.2.27 Diagnostics........................................................................................... 568 9.2.28 Other................................................................................................. 568 9.3 Short description of the operating elements – driving from the crane cab..................................... 569 9.3.1 Driving menu........................................................................................... 569 9.3.2 Transmission........................................................................................... 571 9.3.3 Final drive............................................................................................ 573 9.3.4 Brakes................................................................................................. 574 CCS display.............................................................................................. 574 Side panel from above.................................................................................... 574 9.3.5 Steering............................................................................................... 575 CCS display.............................................................................................. 576 Control panels........................................................................................... 578 10 Starting/switching off the engine – for crane operation........................................................... 579 10.1 When starting the engine for the first time in the day...................................................... 579 10.2 Starting the engine – from the crane cab.................................................................... 581 10.2.1 Check the fuel level and AdBlue level................................................................. 581 Fuel..................................................................................................... 581 AdBlue................................................................................................... 581 10.2.2 Checks before starting the engine..................................................................... 582 Checks on the carrier.................................................................................... 582 Checking the hand-held control........................................................................... 582 At the hydraulic tank.................................................................................... 582 10.2.3 Switching the ignition on............................................................................. 583 10.2.4 Comparison of switching states........................................................................ 584 10.2.5 Display – setting the brightness...................................................................... 584 10.2.6 Starting the engine................................................................................... 585 10.2.7 Checks after starting the engine...................................................................... 586 10.2.8 Setting the idling speed.............................................................................. 587 10.3 Starting the engine – with the hand-held control............................................................ 588 10.4 Switch off the engine....................................................................................... 589 10.4.1 At the ignition lock and with hand-held control....................................................... 589 After switching off...................................................................................... 589 10.4.2 With the idling button................................................................................ 589 10.4.3 Using the emergency stop switches..................................................................... 590 Emergency stop switch, resetting......................................................................... 590 11 Crane operation................................................................................................... 591 11.1 Before operating the crane.................................................................................. 591 11.1.1 CHECKLIST: Checks before operating the crane.......................................................... 591 11.1.2 Check the condition of the truck crane................................................................ 595 Fuel tank auxiliary heater............................................................................... 595 Visual inspection........................................................................................ 595 Checking the position of the hoist ropes................................................................. 596 Checking the electrical system........................................................................... 597 11.1.3 Adjusting the crane cab seat and front control panel.................................................. 598 Crane cab seat........................................................................................... 598 Front control panel...................................................................................... 599 11.1.4 Checking the safety equipment......................................................................... 600 Rated capacity limiter................................................................................... 600 Lifting limit switch..................................................................................... 600 Emergency stop switch.................................................................................... 601 Seat contact switch...................................................................................... 602 11.1.5 Earthing the load..................................................................................... 603 11.1.6 Preheating hydraulic oil.............................................................................. 604 Prerequisites............................................................................................ 604 Preheating............................................................................................... 604 11.1.7 Locking/unlocking the superstructure.................................................................. 605 Locking points........................................................................................... 605 Lock the superstructure.................................................................................. 606 Unlocking the superstructure............................................................................. 606 11.1.8 Switching the houselock on/off........................................................................ 607 Switching on the houselock............................................................................... 607 Switching off the houselock.............................................................................. 609 11.2 Standard slewing range type................................................................................. 611 11.2.1 Permissible slewing ranges and working positions...................................................... 611 360° slewing range....................................................................................... 611 Working position 0° to the rear.......................................................................... 611 180° to the front rigging position....................................................................... 611 11.3 MAXbase slewing range type.................................................................................. 613 11.3.1 Specifications in the lifting capacity tables......................................................... 614 11.3.2 Enabled slewing ranges................................................................................ 615 11.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables.... 618 11.4 Operation of the rated capacity limiter..................................................................... 619 11.4.1 Switch on the RCL..................................................................................... 620 Switching on............................................................................................. 620 11.4.2 Enter rigging mode.................................................................................... 622 Notes on Input........................................................................................... 622 Enter the slewing range type............................................................................. 623 Entering individual components........................................................................... 624 Entering the RCL code.................................................................................... 630 11.4.3 Pre-selecting telescoping............................................................................. 630 11.4.4 Confirm the rigging mode and lifting capacity table................................................... 631 Slewing range type Standard.............................................................................. 631 Slewing range type MAXbase............................................................................... 633 11.4.5 Checks before operating the crane..................................................................... 635 Monitoring menu.......................................................................................... 635 Checking the rigging mode................................................................................ 635 Hoist checking........................................................................................... 637 11.4.6 Display during the crane operation.................................................................... 639 On the RCL display....................................................................................... 639 On the CCSdisplay........................................................................................ 643 11.4.7 RCL early warning..................................................................................... 647 11.4.8 RCL shutdown.......................................................................................... 647 Shutdown due to overload................................................................................. 647 11.4.9 Displaying the lifting capacity tables................................................................ 649 Slewing range type Standard.............................................................................. 649 Slewing range type MAXbase............................................................................... 651 11.4.10 RCL override – version A............................................................................. 653 Overview status display.................................................................................. 653 When rigging............................................................................................. 654 To raise the boom........................................................................................ 655 In emergencies........................................................................................... 656 11.4.11 RCL override – version B............................................................................. 657 11.4.12 Datalogger........................................................................................... 658 Export data.............................................................................................. 658 Display the data......................................................................................... 659 11.5 Crane operation with main boom.............................................................................. 663 11.5.1 Checks during crane operation......................................................................... 663 Horizontal alignment..................................................................................... 663 Safe distances........................................................................................... 663 Checking the wind speed.................................................................................. 664 11.5.2 Main hoist............................................................................................ 665 Switching on the main hoist.............................................................................. 666 Lifting and lowering..................................................................................... 667 Maximum permissible hoist rope speed..................................................................... 668 Switching off the main hoist............................................................................. 668 11.5.3 Auxiliary hoist....................................................................................... 669 Switching on the auxiliary hoist......................................................................... 669 Lifting and lowering..................................................................................... 670 Maximum permissible hoist rope speed..................................................................... 671 Switching off the auxiliary hoist........................................................................ 671 11.5.4 Lifting limit switch and lowering limit switch........................................................ 672 Lifting limit switch..................................................................................... 672 Lowering limit switch.................................................................................... 674 11.5.5 Derricking gear....................................................................................... 675 Switching on the derricking gear......................................................................... 675 Raising and lowering..................................................................................... 676 Maximum derricking speed................................................................................. 677 Re-enable raising function............................................................................... 677 Switching off the derricking gear........................................................................ 678 Lowering the main boom to a horizontal position.......................................................... 678 11.5.6 Telescoping mechanism................................................................................. 679 Overview................................................................................................. 681 Telescoping process...................................................................................... 682 Assignment for display................................................................................... 684 Fixed length, intermediate length, telescoping length.................................................... 685 Telescoping.............................................................................................. 686 Telescoping sequence..................................................................................... 686 Inspections prior to starting operations................................................................. 687 Switching on the telescoping mechanism................................................................... 688 Function of the control lever............................................................................ 688 Switching off the telescoping mechanism.................................................................. 690 Manual telescoping....................................................................................... 691 Checking the initial position,........................................................................... 691 Unlocking the telescoping cylinder....................................................................... 693 Extending/retracting the telescoping cylinder............................................................ 695 Lock telescoping cylinder................................................................................ 696 Unlocking the telescopic section......................................................................... 697 Telescoping the telescopic section....................................................................... 698 Locking the telescopic section........................................................................... 699 Locking the telescopic section for on-road driving....................................................... 700 Telescoping with semi-automaton.......................................................................... 700 Telescoping with pre-selection........................................................................... 702 11.5.7 High-speed mode....................................................................................... 703 Derricking gear Telescoping mechanism.................................................................... 703 Hoists................................................................................................... 703 11.5.8 Slewing gear.......................................................................................... 705 Slewing gear brake....................................................................................... 705 Switching on the slewing gear............................................................................ 706 Releasing the slewing gear brake......................................................................... 706 Applying the slewing gear brake.......................................................................... 706 Slewing.................................................................................................. 707 Permissible slewing speed................................................................................ 708 Braking the slewing movement............................................................................. 709 Slewing gear freewheel................................................................................... 709 Switching off the slewing gear........................................................................... 710 11.5.9 Switching the reduction of slewing speed on and off................................................... 711 Switching reduction off.................................................................................. 711 11.5.10 Possible movement combinations....................................................................... 712 11.6 Settings and displays for crane operation................................................................... 713 11.6.1 Inclining the crane cab............................................................................... 713 11.6.2 Idling speed, setting................................................................................. 714 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper........................................... 714 11.6.4 Limiting the power unit speeds........................................................................ 715 11.6.5 Economy mode.......................................................................................... 716 Switching on............................................................................................. 716 Ending/ switching off.................................................................................... 718 11.6.6 Switching units of measure............................................................................ 718 11.6.7 Setting the characteristic curves for the control levers.............................................. 719 11.6.8 Using the slewable spotlights......................................................................... 720 Manually swinging........................................................................................ 721 Automatic load tracking.................................................................................. 721 11.6.9 Overriding torque reduction........................................................................... 722 11.6.10 Displaying the operating hours....................................................................... 723 11.7 Working range limiter....................................................................................... 725 11.7.1 viewing current settings.............................................................................. 726 On the RCL dislay........................................................................................ 726 In the CCS Start menu.................................................................................... 727 11.7.2 Opening the working range limiter menu................................................................ 727 11.7.3 Enter limit values – for the overall height........................................................... 728 11.7.4 Enter limit values – for the working radius........................................................... 730 11.7.5 Enter limit values – for the slewing range............................................................ 732 11.7.6 Enter limit values – for the hoist rope travel........................................................ 735 11.7.7 Shutdown by working range limiter..................................................................... 737 11.8 Work break.................................................................................................. 739 11.8.1 In case of short work breaks.......................................................................... 739 11.8.2 In case of work breaks of more than 8 hours........................................................... 740 To secure the truck crane................................................................................ 740 11.9 Heating and air-conditioning system......................................................................... 741 11.9.1 Standard heating system............................................................................... 741 Switching on............................................................................................. 741 Heating.................................................................................................. 741 Air distribution......................................................................................... 742 Switching off............................................................................................ 742 11.9.2 Air-conditioning system............................................................................... 743 Notes.................................................................................................... 743 Switching on/off......................................................................................... 743 Cooling, automatic....................................................................................... 744 Cooling, maximum......................................................................................... 744 11.9.3 Auxiliary heater...................................................................................... 745 Switching on............................................................................................. 745 Setting the temperature.................................................................................. 746 Setting the heating start/ heating duration.............................................................. 746 Switching heating start on/off........................................................................... 747 11.10 CraneSTAR system........................................................................................... 748 11.10.1 Overview............................................................................................. 748 11.10.2 Position of the components........................................................................... 748 12 Rigging work...................................................................................................... 749 12.1 Rigging work checklists for crane operation with the main boom.............................................. 749 12.1.1 CHECKLIST: Rigging.................................................................................... 749 12.1.2 CHECKLIST: Unrigging.................................................................................. 755 12.2 Choice of a suitable positioning site....................................................................... 759 12.2.1 Determining the required load-bearing area............................................................ 759 12.2.2 Safe distance from slopes and pits.................................................................... 762 12.2.3 Earthing the truck crane.............................................................................. 763 12.2.4 Safe distance from overhead power lines............................................................... 764 12.3 Rigging work after driving with a dolly..................................................................... 767 12.3.1 Switching off the boom floating position.............................................................. 767 12.3.2 Switching off the slewing gear freewheel.............................................................. 768 Before slewing........................................................................................... 768 12.3.3 Switching off boom pre-tensioning..................................................................... 769 12.4 Connecting/disconnecting the hand-held control.............................................................. 771 12.5 Starting the engine for rigging............................................................................. 775 12.5.1 Starting/shutoff the engine – with the hand-held control.............................................. 775 Prerequisites............................................................................................ 775 Starting the engine...................................................................................... 776 Turning off the engine................................................................................... 776 12.5.2 Starting/shutoff the engine – from the outrigger control units........................................ 777 Prerequisites............................................................................................ 777 Starting the engine...................................................................................... 777 Switch off the engine.................................................................................... 777 12.6 Slewing range – only with the Standard slewing range type................................................... 779 12.6.1 Representation in the lifting capacity tables......................................................... 779 12.6.2 Enabled outrigger spans............................................................................... 780 12.7 Outriggers – Overview – MAXbase slewing range type.......................................................... 781 12.7.1 Definitions........................................................................................... 781 12.7.2 Representation in the lifting capacity tables......................................................... 783 12.7.3 Enabled outrigger spans............................................................................... 784 12.8 Outrigger operation......................................................................................... 789 12.8.1 CHECKLIST: Extending the outriggers................................................................... 789 12.8.2 CHECKLIST: Retracting the outriggers.................................................................. 791 12.8.3 Preparing the truck crane............................................................................. 792 Driver's cab............................................................................................. 792 Crane cab................................................................................................ 792 12.8.4 Setting the outrigger spans........................................................................... 794 For on-road driving...................................................................................... 797 12.8.5 Extending/retracting outrigger beams.................................................................. 797 From the crane cab....................................................................................... 798 From the control units................................................................................... 799 12.8.6 Moving the outrigger pads into operating/driving position............................................. 801 12.8.7 Enlarging the load-bearing area....................................................................... 803 12.8.8 Extending/retracting supporting cylinders............................................................. 804 From the control units................................................................................... 805 From the crane cab....................................................................................... 806 12.8.9 Levelling the truck crane on outriggers horizontally.................................................. 808 Inclination indicators................................................................................... 808 Prerequisites............................................................................................ 809 Manual alignment......................................................................................... 810 Automatic alignment...................................................................................... 810 12.8.10 Levelling the free-standing truck crane.............................................................. 812 12.8.11 Operating the axle raising system.................................................................... 814 12.8.12 Outrigger pressure display........................................................................... 816 12.9 Rigging/unrigging the counterweight......................................................................... 819 12.9.1 Information on rigging................................................................................ 819 When rigging............................................................................................. 819 When unrigging........................................................................................... 820 12.9.2 Counterweight sections................................................................................ 821 Version 1................................................................................................ 821 Version 2................................................................................................ 821 Version 3................................................................................................ 822 12.9.3 Identification........................................................................................ 823 12.9.4 Slinging points on the counterweight sections......................................................... 824 12.9.5 CHECKLIST: Rigging the counterweight.................................................................. 825 12.9.6 CHECKLIST: Unrigging the counterweight................................................................ 827 12.9.7 Assembling counterweight combination.................................................................. 828 Setting down the 2.3 t base plate........................................................................ 829 Setting down the top couterweight section................................................................ 829 Version 1................................................................................................ 830 Version 2................................................................................................ 838 Version 3................................................................................................ 842 12.9.8 Counterweight hoist unit.............................................................................. 850 Counterweight menu....................................................................................... 850 Extending/retracting the lifting cylinders............................................................... 851 Automatic mode rigging................................................................................... 853 Automatic mode unrigging................................................................................. 855 Cancel automatic mode.................................................................................... 856 12.9.9 Removing/installing the counterweight on the turntable................................................ 857 Removing................................................................................................. 857 Installing............................................................................................... 858 12.9.10 Setting down counterweight for driving............................................................... 859 Versions 1 and 3......................................................................................... 859 Version 2................................................................................................ 861 12.9.11 Slewing with rigged counterweight.................................................................... 861 12.10 Rigging work on the main boom.............................................................................. 863 12.10.1 Hook block on the bumper............................................................................. 863 Picking up the hook block................................................................................ 863 Attaching the hook block................................................................................. 864 12.10.2 Hook block on a separate vehicle..................................................................... 865 Picking up the hook block................................................................................ 866 Setting down the hook block.............................................................................. 866 12.10.3 Hook block, separable................................................................................ 868 Rigging for on- road driving............................................................................. 868 Rigging for crane operation.............................................................................. 869 12.10.4 Hook block with ballast plates....................................................................... 870 Removing................................................................................................. 870 Installing............................................................................................... 871 Information on crane operation........................................................................... 871 12.10.5 Reeving and unreeving the hoist rope................................................................. 872 Version A................................................................................................ 872 Version B................................................................................................ 873 Reeving the hoist rope................................................................................... 875 Unreeving hoist rope..................................................................................... 879 12.10.6 Possible reevings on the main boom................................................................... 880 With 6 head sheaves...................................................................................... 880 With 8 head sheaves...................................................................................... 883 With 9 head sheaves...................................................................................... 886 12.10.7 Installing/removing the lifting limit switch......................................................... 887 Installing the lifting limit switch...................................................................... 887 Removing the lifting limit switch........................................................................ 890 12.10.8 Locking/unlocking the lifting limit switch........................................................... 892 Locking.................................................................................................. 892 Removing the lock........................................................................................ 892 12.10.9 Anemometer and air traffic control light............................................................. 893 Installing............................................................................................... 893 Switching on/off......................................................................................... 894 Removing................................................................................................. 895 12.11 Other rigging work......................................................................................... 897 12.11.1 Railings on the turntable............................................................................ 897 12.11.2 Folding the mirrors in and out, and adjusting them................................................... 898 12.11.3 Slinging points for personal protective equipment.................................................... 899 12.11.4 Cameras for crane operation.......................................................................... 900 Camera on main boom...................................................................................... 900 Camera on the hoists..................................................................................... 903 Camera on the driver's cab............................................................................... 903 Operating the camera..................................................................................... 904 12.11.5 Step at the crane cab................................................................................ 905 13 Driving with a rigged truck crane................................................................................. 907 13.1 Route....................................................................................................... 907 13.2 Permissible rigging modes and axle loads.................................................................... 908 Axle load table.............................................................................................. 908 13.2.1 To drive without a load............................................................................... 911 13.2.2 To drive with a load.................................................................................. 911 13.2.3 Axle loads............................................................................................ 912 13.3 Before driving the rigged truck crane....................................................................... 913 13.3.1 Check the tyre pressures and wind speed............................................................... 913 13.3.2 Secure the superstructure against slewing............................................................. 913 13.3.3 Putting the truck crane on the wheels – with Raise axle function...................................... 914 13.3.4 Putting the truck crane on the wheels – with the outriggers........................................... 916 13.4 Driving from the driver's cab............................................................................... 919 13.4.1 Preparing to drive.................................................................................... 919 Transmission............................................................................................. 919 Switching on separate steering........................................................................... 919 Connections.............................................................................................. 919 13.4.2 Whilst driving........................................................................................ 920 13.4.3 After driving......................................................................................... 921 13.5 Driving from the crane cab.................................................................................. 923 13.5.1 Preparing to drive.................................................................................... 924 13.5.2 Opening/closing the driving menu...................................................................... 925 Opening the menu......................................................................................... 925 Selecting the operating mode............................................................................. 925 Crane's hydraulic system Driving mode.................................................................... 927 Closing menu............................................................................................. 927 13.5.3 Steering.............................................................................................. 928 Switching on............................................................................................. 928 Display and steering direction........................................................................... 928 Switching the steering direction......................................................................... 929 Displays when steering................................................................................... 929 Separate steering........................................................................................ 930 Normal steering mode..................................................................................... 933 13.5.4 Operating the transmission............................................................................ 934 Selecting the transmission mode.......................................................................... 934 13.5.5 Whilst driving........................................................................................ 935 DM and RM transmission mode.............................................................................. 935 Transmission mode D...................................................................................... 935 Warning messages......................................................................................... 935 13.5.6 Possible connections.................................................................................. 936 Longitudinal/ transverse differential locks.............................................................. 936 13.5.7 After driving......................................................................................... 938 14 Malfunctions during crane operation............................................................................... 939 14.1 Emergency stop switch....................................................................................... 939 14.2 What to do when malfunctions occur during crane operation................................................... 940 The load can be set down..................................................................................... 940 Load cannot be set down...................................................................................... 940 14.3 Warning and error messages.................................................................................. 941 Program version.............................................................................................. 941 14.3.1 Warning messages on the CCS display................................................................... 941 Meaning of the symbols................................................................................... 942 14.3.2 Error messages on the CCS display..................................................................... 946 14.3.3 Warning messages on the RCL display................................................................... 948 14.4 Troubleshooting............................................................................................. 953 14.4.1 Malfunctions on the engine............................................................................ 953 14.4.2 Malfunctions on the main hoist/auxiliary hoist........................................................ 953 14.4.3 Malfunctions in the hoist cameras..................................................................... 955 14.4.4 Malfunctions in the main boom camera.................................................................. 955 14.4.5 Malfunctions on the derricking gear................................................................... 956 14.4.6 Malfunctions in the telescoping mechanism............................................................. 957 14.4.7 Malfunctions on the slewing gear...................................................................... 958 14.4.8 Malfunctions on the counterweight hoist unit.......................................................... 960 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler............................................. 960 14.4.10 Malfunctions when operating with the hand-held control............................................... 961 14.4.11 Malfunctions when inclining the crane cab............................................................ 961 14.4.12 Malfunctions when raising the axles.................................................................. 961 14.4.13 Malfunctions of the outriggers....................................................................... 962 14.4.14 Malfunctions on the turntable lock................................................................... 962 14.4.15 Malfunctions on the CCS/RCL control units............................................................ 963 14.4.16 Malfunctions when driving from the crane cab......................................................... 963 14.4.17 Malfunctions on the CraneSTAR system................................................................. 964 14.5 Emergency operations and programs........................................................................... 967 14.5.1 Mechanical emergency activation for retracting........................................................ 968 Prior to the emergency operation, check.................................................................. 968 Procedure................................................................................................ 968 Mechanical emergency activation.......................................................................... 969 14.5.2 Telescoping emergency program......................................................................... 971 Telescoping emergency program menu....................................................................... 971 Determining the type of error............................................................................ 972 Error at the length indicator............................................................................ 973 Tables for approaching the locking points................................................................ 977 14.5.3 Entering the current telescoping...................................................................... 979 14.5.4 Emergency operation with the hand-held control........................................................ 981 To pre-select a power unit............................................................................... 982 Operating a power unit................................................................................... 982 Stopping movements....................................................................................... 983 Stopping movements in emergencies........................................................................ 984 Switch off the engine.................................................................................... 984 14.5.5 Notes on slewing in emergency operation............................................................... 984 For the Standard slewing range type...................................................................... 984 For the MAXbase slewing range type....................................................................... 986 14.5.6 Rotate for overridden slewing gear shutdown........................................................... 987 14.6 Hydraulic emergency operation with the hand pump............................................................ 989 14.6.1 Operating principle................................................................................... 989 14.6.2 Switching over the crane's hydraulic system........................................................... 990 14.6.3 Establishing the hydraulic circuits required.......................................................... 991 Releasing/ securing valves............................................................................... 991 Switching over valves.................................................................................... 992 For lowering............................................................................................. 993 14.6.4 Performing emergency activation....................................................................... 994 14.6.5 After emergency activation............................................................................ 995 14.7 Hydraulic emergency operation acc. to BGR 159............................................................... 997 14.7.1 Applications and function............................................................................. 997 14.7.2 CHECKLIST: Emergency operation........................................................................ 999 14.7.3 CHECKLIST: After emergency operation..................................................................1000 14.7.4 Connecting/removing transformer – for self-sufficiency................................................1001 Connecting...............................................................................................1001 Removing.................................................................................................1002 14.7.5 Switching emergency operation on/off..................................................................1003 14.7.6 Connecting/removing transformer – for external energy source..........................................1004 14.7.7 Establishing the required hydraulic circuits..........................................................1005 Valves at the control panel..............................................................................1005 For lifting/ lowering....................................................................................1007 For slewing..............................................................................................1008 14.7.8 Performing emergency operation........................................................................1009 Slewing..................................................................................................1009 Derricking...............................................................................................1010 Lifting/lowering.........................................................................................1010 14.7.9 Emergency supply of another crane.....................................................................1011 For emergency supply.....................................................................................1011 After emergency supply...................................................................................1011 14.8 Fuses in the crane cab......................................................................................1013 Information on changing fuses................................................................................1013 Index....................................................................................................................1019 A....................................................................................................................1021 B....................................................................................................................1021 C....................................................................................................................1022 D....................................................................................................................1024 E....................................................................................................................1026 F....................................................................................................................1028 H....................................................................................................................1028 I....................................................................................................................1029 L....................................................................................................................1029 M....................................................................................................................1030 O....................................................................................................................1031 P....................................................................................................................1033 R....................................................................................................................1033 S....................................................................................................................1034 T....................................................................................................................1035 V....................................................................................................................1037 W....................................................................................................................1037
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