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Grove Crane GMK 5250XL-1 Operating Instruction Manual – PDF DOWNLOAD
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Description
Grove Crane GMK 5250XL-1 Operating Instruction Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5250XL-1 Operating Instruction Manual – PDF DOWNLOAD
Language : English
Pages : 1014
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5250XL-1 Operating Instruction Manual – PDF DOWNLOAD
Overview:
Accidents:
- In the event of an accident, contact the relevant branch office of Manitowoc Crane Care in the country in which you are working and specify your crane type and serial number.
- Observe the accident reporting regulations prevailing in the country in which you are working and inform the supervisory authorities responsible for the type of accident (for example, material damage, injuries to persons).
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 5250XL-1 Operating Instruction Manual – PDF DOWNLOAD
Operating Instructions....................................................................................................... 1 Table of content ........................................................................................................ 5 General.................................................................................................................. 35 1 Overview........................................................................................................... 35 1.1 Accidents.................................................................................................... 35 1.2 Branch offices............................................................................................... 37 1.2.1 Manitowoc Crane Care................................................................................... 37 1.2.2 Dealer list............................................................................................ 37 1.3 Warranty specifications...................................................................................... 37 1.4 Terms used................................................................................................... 38 1.5 Technical data............................................................................................... 41 1.5.1 Maximum lifting capacity (DIN/ ISO/ EN)................................................................ 41 1.5.2 Dimensions and weights of the truck crane, axle loads.................................................. 42 Dimensions............................................................................................... 43 Weight and axle loads.................................................................................... 43 1.5.3 Dimensions and weights of removable parts.............................................................. 44 Spare wheel.............................................................................................. 44 Outriggers............................................................................................... 44 Main boom................................................................................................ 45 Hook blocks and hook tackle.............................................................................. 45 Hook blocks, split....................................................................................... 46 Auxiliary hoist.......................................................................................... 47 Counterweight parts...................................................................................... 47 Version 1................................................................................................ 47 Version 2................................................................................................ 48 1.5.4 Carrier................................................................................................ 49 Engine................................................................................................... 49 Transmission............................................................................................. 49 Transfer case............................................................................................ 49 Axle lines............................................................................................... 50 Steering................................................................................................. 50 Tyres.................................................................................................... 50 Electrical system........................................................................................ 50 Tool..................................................................................................... 51 Towing couplings......................................................................................... 51 Driving speeds........................................................................................... 51 Climbing ability......................................................................................... 51 Outriggers............................................................................................... 52 Turning radii............................................................................................ 53 1.5.5 Superstructure......................................................................................... 54 Main hoist............................................................................................... 54 Auxiliary hoist.......................................................................................... 54 Slewing gear............................................................................................. 54 Derricking gear.......................................................................................... 55 Main boom................................................................................................ 55 Lattice extension........................................................................................ 55 Operating speeds......................................................................................... 56 Noise emission........................................................................................... 56 1.6 Documentation supplied....................................................................................... 57 1.6.1 Questions on documentation............................................................................. 58 1.7 Notes on the operating manual................................................................................ 59 1.7.1 What do the symbols used mean?......................................................................... 59 1.7.2 How is the operating manual structured?................................................................ 61 Division................................................................................................. 61 Structure of the chapters................................................................................ 61 Structure of the pages................................................................................... 62 1.7.3 How do I find the information I need?.................................................................. 63 Cross-references example................................................................................. 64 1.7.4 What information is available for operations planning?................................................. 66 1.8 Conversion table for US measuring units...................................................................... 67 1.9 Training – Information....................................................................................... 69 1.10 Identification.............................................................................................. 70 1.11 EC Declaration of Conformity................................................................................ 72 2 Basic safety instructions.......................................................................................... 73 2.1 Intended use................................................................................................. 73 2.1.1 Improper use........................................................................................... 74 2.2 Organisational measures...................................................................................... 75 2.3 Personnel qualifications..................................................................................... 77 2.4 Safety instructions for driving the truck crane.............................................................. 78 2.5 Safety instructions for crane operation...................................................................... 79 2.6 Instructions on transporting persons......................................................................... 82 Equipment for lifting persons................................................................................ 82 Personnel.................................................................................................... 83 Operation.................................................................................................... 83 Truck crane.................................................................................................. 84 Driving ................................................................................................................. 85 3 Operating elements for driving..................................................................................... 85 3.1 Overview of the operating elements........................................................................... 85 3.1.1 Exterior of the truck crane............................................................................ 86 3.1.2 Driver's cab........................................................................................... 90 Overview................................................................................................. 90 Behind the cover......................................................................................... 94 In the rear of the driver's cab.......................................................................... 94 3.1.3 Steering column/steering wheel......................................................................... 95 3.1.4 Instrument panel....................................................................................... 97 Left/right............................................................................................... 97 Middle................................................................................................... 98 3.1.5 Transmission operating elements........................................................................ 100 3.1.6 On-board computer...................................................................................... 101 3.1.7 Tachograph............................................................................................. 102 3.1.8 Heating/Air-conditioning system........................................................................ 103 Standard heating system.................................................................................. 103 Auxiliary water heating system........................................................................... 104 Auxiliary air heater..................................................................................... 105 3.1.9 CCS control unit....................................................................................... 106 3.1.10 CCS – Menu-independent displays....................................................................... 108 3.1.11 CCS – Start menu...................................................................................... 109 3.1.12 CCS – Overview of menu groups......................................................................... 110 3.1.13 Carrier menu group.................................................................................... 112 Suspension/level adjustment menu......................................................................... 113 Driving menu............................................................................................. 114 Exhaust system menu...................................................................................... 115 Air intake inhibitor menu................................................................................ 116 3.1.14 Settings menu group................................................................................... 117 Set display brightness and date/time menu................................................................ 118 3.1.15 Information menu group................................................................................ 119 Operating hours menu..................................................................................... 120 Engine/transmission error menu........................................................................... 121 Crane operation error menu............................................................................... 122 3.1.16 Various controls menu group........................................................................... 123 3.1.17 Emergency operations menu group....................................................................... 124 3.1.18 Outrigger control units............................................................................... 125 3.2 Brief description of the operating elements.................................................................. 127 3.2.1 Definition of direction information.................................................................... 128 Basic rule............................................................................................... 128 Switches and buttons..................................................................................... 128 3.2.2 General rules for buttons and symbols on the display................................................... 129 3.2.3 Engine................................................................................................. 130 Steering column.......................................................................................... 130 On the steering wheel.................................................................................... 130 Instrument panel......................................................................................... 131 3.2.4 AdBlue (DEF) system/Exhaust gas emission control system/ Regeneration.................................. 132 Instrument panel......................................................................................... 132 CCS display.............................................................................................. 133 3.2.5 Air intake inhibitor................................................................................... 135 3.2.6 Battery master switch.................................................................................. 136 3.2.7 Electrical system...................................................................................... 137 3.2.8 CCS crane control system............................................................................... 138 3.2.9 Transmission........................................................................................... 140 Transmission control unit................................................................................ 140 Driving mode display..................................................................................... 141 3.2.10 Reverse camera........................................................................................ 143 3.2.11 BirdView system 270°.................................................................................. 144 3.2.12 Transfer case......................................................................................... 146 3.2.13 Final drive........................................................................................... 147 3.2.14 Brakes................................................................................................ 149 Service brake............................................................................................ 149 Additional brakes........................................................................................ 149 Parking brake............................................................................................ 150 3.2.15 Steering/separate steering............................................................................ 152 Instrument panel......................................................................................... 152 CCS display.............................................................................................. 154 3.2.16 Suspension............................................................................................ 156 CCS display.............................................................................................. 156 3.2.17 Lighting/windscreen wipers/horn....................................................................... 157 Steering column.......................................................................................... 157 Steering wheel........................................................................................... 157 Instrument panel......................................................................................... 157 CCS display.............................................................................................. 160 Roof..................................................................................................... 160 3.2.18 Level adjustment system............................................................................... 161 3.2.19 Tachograph/speedometer................................................................................ 163 Tachograph............................................................................................... 163 Cover.................................................................................................... 163 Speedometer.............................................................................................. 163 3.2.20 Diagnostics........................................................................................... 164 3.2.21 On-board computer..................................................................................... 165 3.2.22 Windows, doors, keys.................................................................................. 167 Window winder............................................................................................ 167 Doors.................................................................................................... 168 Keys..................................................................................................... 168 3.2.23 Ladders and access ladders............................................................................ 169 Access ladders........................................................................................... 169 Ladders.................................................................................................. 170 3.2.24 Front flap............................................................................................ 172 4 Starting/switching off the engine – for driving.................................................................... 173 4.1 Starting the engine from the driver's cab.................................................................... 173 4.1.1 CHECKLIST: Starting the engine......................................................................... 174 4.1.2 CHECKLIST: At low temperatures......................................................................... 177 4.1.3 Refuelling............................................................................................. 178 Standard tank............................................................................................ 178 Dual- tank............................................................................................... 179 AdBlue................................................................................................... 180 4.1.4 Checks before starting the engine...................................................................... 181 At the hydraulic tank.................................................................................... 181 Battery master switch.................................................................................... 182 Checking the hand-held control........................................................................... 182 4.1.5 Switching on the ignition.............................................................................. 183 4.1.6 Lamp test/comparison of the switching states........................................................... 184 Lamp test................................................................................................ 184 Comparison of the switching states....................................................................... 184 4.1.7 Display – Setting the brightness....................................................................... 185 4.1.8 Starting the engine.................................................................................... 186 4.1.9 Starting the engine – at the outrigger control units................................................... 188 Prerequisites............................................................................................ 188 Starting the engine...................................................................................... 188 4.1.10 Checks after starting the engine...................................................................... 189 Start menu and on-board computer......................................................................... 189 Instrument panel......................................................................................... 190 4.1.11 Monitoring elements................................................................................... 192 Instrument panel......................................................................................... 192 4.1.12 Setting the idling speed.............................................................................. 193 4.2 Switching off the engine..................................................................................... 195 4.2.1 On the ignition lock/on the outrigger control units.................................................... 195 After switching off...................................................................................... 195 4.2.2 Using the emergency stop switches...................................................................... 196 Resetting the emergency stop switch...................................................................... 196 4.3 Air intake inhibitor......................................................................................... 197 Opening the air intake inhibitor............................................................................. 197 5 Driving............................................................................................................ 199 5.1 Before driving............................................................................................... 199 5.1.1 CHECKLIST: Checks before on-road driving............................................................... 199 5.1.2 Checking the condition of the truck crane.............................................................. 205 Electrical system........................................................................................ 205 Adjusting the mirrors.................................................................................... 205 Warning plates for vehicle width......................................................................... 207 Vehicle height display................................................................................... 207 Supply pressure.......................................................................................... 208 Parking brake............................................................................................ 209 5.1.3 Adjusting the seat and the steering column............................................................. 210 Driver's seat............................................................................................ 210 Passenger's seat......................................................................................... 211 Adjusting the steering column............................................................................ 212 5.1.4 Switching the suspension on/off........................................................................ 213 Opening the menu......................................................................................... 213 Switching on the suspension.............................................................................. 214 Switching off the suspension............................................................................. 214 5.1.5 Setting the tachograph................................................................................. 215 Prerequisites............................................................................................ 215 In the event of malfunctions............................................................................. 215 Setting the tachograph................................................................................... 216 5.1.6 Setting the time....................................................................................... 220 5.1.7 Displaying and resetting operating hours............................................................... 221 5.2 Operating the transmission................................................................................... 223 5.2.1 Switching on........................................................................................... 223 5.2.2 Shifting the transmission to neutral position.......................................................... 224 5.2.3 Selecting the direction of travel and starting gear.................................................... 225 Selecting the driving direction.......................................................................... 225 Selecting the starting gear.............................................................................. 226 5.2.4 Changing the operating mode............................................................................ 227 Changing to automatic mode............................................................................... 227 Changing to manual mode.................................................................................. 227 5.2.5 Starting driving....................................................................................... 228 5.2.6 Driving and changing gears............................................................................. 229 In automatic operating mode.............................................................................. 229 In manual operating mode................................................................................. 230 5.2.7 Changing the driving direction......................................................................... 231 5.2.8 Stopping the truck crane............................................................................... 231 Stopping for a long period of time....................................................................... 231 5.2.9 On the roller type dynamometer......................................................................... 232 5.2.10 Preheating the transmission........................................................................... 232 5.3 Driving and parking the truck crane.......................................................................... 233 5.3.1 Checks while driving................................................................................... 233 Immediately after you start to move...................................................................... 233 While driving............................................................................................ 235 5.3.2 Cruise control......................................................................................... 237 Switching on............................................................................................. 237 Switching off............................................................................................ 237 5.3.3 Temposet............................................................................................... 238 Switching on............................................................................................. 238 Switching off............................................................................................ 238 5.3.4 Driving downhill....................................................................................... 239 Starting driving......................................................................................... 239 Checks when driving downhill............................................................................. 240 Downshifting............................................................................................. 240 Additional brakes........................................................................................ 241 5.3.5 Driving uphill......................................................................................... 242 Starting driving......................................................................................... 242 Driving.................................................................................................. 242 5.3.6 Torque reduction....................................................................................... 243 AdBlue (DEF) tank........................................................................................ 243 System malfunction....................................................................................... 244 5.3.7 Overriding torque reduction............................................................................ 246 5.3.8 Cleaning the exhaust system............................................................................ 247 Automatic cleaning....................................................................................... 247 Manual cleaning.......................................................................................... 248 Disabling cleaning....................................................................................... 250 5.3.9 Parking the truck crane................................................................................ 251 Securing against rolling away............................................................................ 251 When stationary for more than 8 hours.................................................................... 252 5.3.10 Folding berth......................................................................................... 253 5.4 Off-road driving............................................................................................. 255 Adjustments to the transmission.............................................................................. 255 Connections.................................................................................................. 255 Changing the vehicle level................................................................................... 255 Rocking the vehicle free and towing.......................................................................... 255 5.4.1 Transfer case – switching the off-road gear on/off..................................................... 256 5.4.2 Longitudinal and transverse differential locks......................................................... 257 5.4.3 Operating the level adjustment system.................................................................. 259 Opening the menu......................................................................................... 259 Setting the on-road level................................................................................ 260 Pre-selecting suspension struts.......................................................................... 260 Changing the vehicle level............................................................................... 261 Viewing the current inclination.......................................................................... 261 Exiting the menu......................................................................................... 262 5.4.4 Freeing a stuck truck crane............................................................................ 263 Rocking the truck crane free............................................................................. 263 Towing free forwards..................................................................................... 264 Towing free in reverse gear.............................................................................. 264 5.5 Separate steering............................................................................................ 265 5.5.1 Switching to separate steering......................................................................... 265 Manual................................................................................................... 266 Automatic................................................................................................ 267 5.6 Heating and air-conditioning system.......................................................................... 269 5.6.1 Standard heating system................................................................................ 269 Switching on............................................................................................. 269 Heating.................................................................................................. 269 Air distribution......................................................................................... 270 Examples................................................................................................. 271 Switching off............................................................................................ 271 5.6.2 Air-conditioning system................................................................................ 272 Notes.................................................................................................... 272 Switching on/off......................................................................................... 272 Cooling.................................................................................................. 273 Drying................................................................................................... 273 5.6.3 Auxiliary water heater................................................................................. 274 Preheating the engine.................................................................................... 274 Preheating the driver's cab.............................................................................. 275 Switching on the auxiliary heater........................................................................ 276 Switching off the auxiliary heater....................................................................... 277 Setting time and weekday................................................................................. 277 Saving automatic heating start........................................................................... 278 Error messages........................................................................................... 280 5.6.4 Auxiliary air heater................................................................................... 282 Switching on............................................................................................. 282 Temperature.............................................................................................. 283 Switching off............................................................................................ 283 Other functions.......................................................................................... 283 5.6.5 Radio.................................................................................................. 284 5.7 Towing a trailer............................................................................................. 285 Effects on the axle loads.................................................................................... 285 Coupling the trailer......................................................................................... 286 Connecting the supply lines.................................................................................. 287 Removing the supply lines.................................................................................... 288 Uncoupling the trailer....................................................................................... 288 Checking the braking force................................................................................... 290 6 Driving modes and rigging for on-road driving...................................................................... 291 6.1 Driving modes................................................................................................ 291 Information about the axle loads............................................................................. 291 6.1.1 Information on how to use the tables................................................................... 292 6.1.2 Tables for a maximum axle load of 12 t................................................................. 293 For tyres 385/95 R25..................................................................................... 293 For tyres 445/95 R25..................................................................................... 294 Fort tyres 525/80 R 25................................................................................... 295 6.1.3 Maximum permitted speeds with an axle load greater than 12 t........................................... 296 6.2 Weighing the truck crane..................................................................................... 297 Axle groups.................................................................................................. 298 Weighing procedure........................................................................................... 299 Evaluation................................................................................................... 300 6.3 Rigging work for driving with a dolly........................................................................ 301 6.3.1 Switching on the slewing gear freewheel................................................................ 302 6.3.2 Switching on the boom floating position................................................................ 303 6.3.3 Switching on boom pre-tensioning....................................................................... 304 6.3.4 3rd Axle raising/lowering.............................................................................. 305 6.4 Rigging the main boom........................................................................................ 307 Additional equipment required................................................................................ 307 6.4.1 CHECKLIST: Removing the main boom...................................................................... 308 Prerequisites............................................................................................ 308 Checklist................................................................................................ 308 6.4.2 CHECKLIST: Mounting the main boom...................................................................... 310 Prerequisites............................................................................................ 310 Checklist................................................................................................ 310 6.4.3 Slinging the main boom................................................................................. 312 Marking.................................................................................................. 312 Installing the lifting gear.............................................................................. 312 Removing the lifting gear................................................................................ 313 6.4.4 Removing/inserting the derricking cylinder head axle................................................... 314 Operating the lifting device............................................................................. 314 Pulling the derricking cylinder head axle................................................................ 315 Fitting the derricking cylinder head axle................................................................ 316 6.4.5 Retracting/extending the boom pivot pin................................................................ 317 Before retracting........................................................................................ 317 After extending.......................................................................................... 318 Retracting/ extending the pivot pin...................................................................... 319 6.4.6 Disconnecting/connecting hydraulic/electrical connections.............................................. 320 Disconnecting............................................................................................ 320 Establishing............................................................................................. 321 6.4.7 Lifting the main boom off/onto the turntable........................................................... 322 Lifting from the turntable............................................................................... 322 Lifting onto the turntable............................................................................... 323 6.4.8 Aligning the connecting points......................................................................... 323 6.4.9 Transporting the main boom............................................................................. 324 6.4.10 Checks after installing the main boom................................................................. 325 6.5 Removing/installing the outrigger beams...................................................................... 327 6.5.1 CHECKLIST: Removing the outrigger beams................................................................ 328 6.5.2 CHECKLIST: Installing the outrigger beams.............................................................. 330 6.5.3 Preparations – for removal............................................................................. 332 6.5.4 Preparations – for installation/removal using the auxiliary crane...................................... 332 Prerequisites............................................................................................ 332 6.5.5 Preparations – for installation/removal using the truck crane.......................................... 333 Prerequisites............................................................................................ 333 Special outrigger span................................................................................... 333 6.5.6 Removing/attaching outrigger pads...................................................................... 335 Removing the outrigger pads.............................................................................. 335 Attaching the outrigger pads............................................................................. 336 6.5.7 Disconnecting/establishing hydraulic connection........................................................ 337 6.5.8 Disconnecting/establishing the electrical connection................................................... 338 6.5.9 Unscrewing/screwing in the spacers..................................................................... 339 Unscrewing............................................................................................... 339 Screwing in.............................................................................................. 340 6.5.10 Disconnecting/establishing the connections to the supporting box...................................... 341 6.5.11 Extending/retracting the outrigger beam............................................................... 341 Extending the outrigger beam............................................................................. 341 Inserting the outrigger beam............................................................................. 343 6.5.12 Transporting the outrigger beams...................................................................... 345 6.5.13 Note on error messages with removed outrigger beams................................................... 346 6.6 Rigging the auxiliary hoist.................................................................................. 347 6.6.1 CHECKLIST: Installing the auxiliary hoist.............................................................. 347 Prerequisites............................................................................................ 347 6.6.2 CHECKLIST: Removing the auxiliary hoist................................................................ 349 Prerequisites............................................................................................ 349 6.6.3 Slinging the auxiliary hoist........................................................................... 352 6.6.4 Slinging the rigging frame............................................................................. 352 6.6.5 Lowering/raising the rigging frame..................................................................... 353 Prerequisite............................................................................................. 353 6.6.6 Placing the auxiliary hoist on the counterweight combination........................................... 353 6.6.7 Establishing/disconnecting the hydraulic connection.................................................... 354 6.6.8 Establishing/disconnecting the electrical connection................................................... 355 6.6.9 Making/breaking the connection to the central lubrication.............................................. 356 6.6.10 Establishing/removing the connection to the turntable................................................. 357 Establishing a connection................................................................................ 357 Disconnecting a connection............................................................................... 359 6.6.11 Securing the hoist rope............................................................................... 360 6.6.12 Transporting the auxiliary hoist...................................................................... 361 6.6.13 Checking that the auxiliary hoist is functioning properly............................................. 362 Slewing direction........................................................................................ 362 Slewing indicator........................................................................................ 362 6.6.14 Rigging aid for the hoist rope........................................................................ 363 7 Transportation..................................................................................................... 365 7.1 Transport with transport vehicle............................................................................. 365 7.1.1 CHECKLIST: Checks before transport..................................................................... 366 7.1.2 Driving the truck crane on to the transport vehicle and lashing down................................... 368 7.2 Transport by ship............................................................................................ 371 7.2.1 Additional battery master switch....................................................................... 372 Switching on/off......................................................................................... 372 8 Malfunctions in driving mode....................................................................................... 373 8.1 Emergency stop switch........................................................................................ 373 8.2 Procedure in the event of malfunctions....................................................................... 374 8.2.1 Procedure in the event of a malfunction in road traffic................................................ 374 8.2.2 Procedure in the event of engine malfunctions.......................................................... 375 8.2.3 Procedure in the event of transmission malfunctions.................................................... 376 8.3 Warning and error messages................................................................................... 377 Program version.............................................................................................. 377 8.3.1 Warning and malfunction messages on the instrument panel............................................... 377 Meaning of the lamps..................................................................................... 377 8.3.2 Warning and malfunction messages on the on-board computer display...................................... 379 Messages................................................................................................. 379 Symbols.................................................................................................. 380 8.3.3 Warning messages on the CCS display.................................................................... 383 Representation of the symbol frame....................................................................... 383 Symbols on the CCS display............................................................................... 384 8.3.4 Engine/transmission error messages..................................................................... 396 Opening the menu......................................................................................... 396 Exiting the menu......................................................................................... 396 8.4 Troubleshooting.............................................................................................. 397 8.4.1 Engine malfunctions.................................................................................... 397 8.4.2 Faults on the Adblue (DEF) system...................................................................... 399 8.4.3 Malfunctions in the transmission....................................................................... 400 8.4.4 Service brake malfunctions............................................................................. 401 8.4.5 Malfunctions of the steering........................................................................... 402 8.4.6 Differential lock malfunctions......................................................................... 403 8.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler.............................................. 403 8.4.8 Malfunctions on the suspension......................................................................... 404 8.4.9 Malfunctions of the level adjustment system............................................................ 404 8.4.10 Malfunction in the CCS control unit................................................................... 404 8.5 Emergency operation and breakdown assistance................................................................. 405 8.5.1 Externally starting the truck crane.................................................................... 405 8.5.2 Battery charger........................................................................................ 406 Prerequisites............................................................................................ 406 8.5.3 Towing the truck crane................................................................................. 407 Important information.................................................................................... 407 In the case of engine/transmission damage................................................................ 407 Tow starting............................................................................................. 410 8.5.4 Wheel change........................................................................................... 411 Removing a damaged wheel................................................................................. 411 On the spare wheel holder................................................................................ 412 Mounting a wheel......................................................................................... 414 8.5.5 Inflating the tyres yourself........................................................................... 415 Connecting the filling hose.............................................................................. 415 Inflating the tyres...................................................................................... 416 Remove the filling hose.................................................................................. 416 8.6 Fuses........................................................................................................ 417 Notes on changing fuses...................................................................................... 417 8.6.1 Fuses in the driver's cab.............................................................................. 418 Group F1................................................................................................. 418 Group F2................................................................................................. 419 Group F3................................................................................................. 419 Group F4................................................................................................. 420 Group F6................................................................................................. 420 Other fuses.............................................................................................. 421 8.6.2 Fuses in the battery box............................................................................... 422 Crane operation.......................................................................................................... 423 9 Operating elements for crane operation............................................................................. 423 9.1 Overview of the operating elements........................................................................... 423 9.1.1 Exterior of the truck crane............................................................................ 424 9.1.2 Crane cab.............................................................................................. 428 Side panel............................................................................................... 430 Crane cab, rear.......................................................................................... 432 Console, rear............................................................................................ 434 9.1.3 Control panels......................................................................................... 435 Left..................................................................................................... 435 Right.................................................................................................... 436 9.1.4 Control lever configuration............................................................................ 437 Version 1................................................................................................ 437 Version 2................................................................................................ 438 9.1.5 Heating/Air-conditioning system........................................................................ 440 9.1.6 CCS control unit....................................................................................... 442 9.1.7 Menu-independent displays.............................................................................. 444 9.1.8 CCS – Start menu....................................................................................... 445 RCL display.............................................................................................. 446 Slewing ranges/ working radii display.................................................................... 447 9.1.9 CCS – Overview of menu groups.......................................................................... 448 9.1.10 Superstructure menu group............................................................................. 452 Superstructure lock menu................................................................................. 453 Counterweight menu....................................................................................... 454 9.1.11 Outrigger/driving menu group.......................................................................... 455 Outrigger menu........................................................................................... 456 Outrigger cylinders menu................................................................................. 458 Exhaust system menu...................................................................................... 460 Air intake inhibitor menu................................................................................ 461 9.1.12 RCL/Telescoping menu group............................................................................ 463 Enter rigging mode/telescope status menu................................................................. 464 Pre-selection telescoping menu........................................................................... 468 Lifting capacity tables menu............................................................................. 470 Telescoping semi-automation menu......................................................................... 471 Manual telescoping menu.................................................................................. 472 9.1.13 Working range limiter menu group...................................................................... 473 Overall height menu...................................................................................... 474 Working radius menu...................................................................................... 475 Slewing angle menu....................................................................................... 476 Hoist rope travel limitation menu........................................................................ 477 9.1.14 Information menu group 1.............................................................................. 478 Hydraulic pressure and fuel consumption menu............................................................. 479 9.1.15 Engine/Additional equipment menu group................................................................ 480 Remote control menu...................................................................................... 481 Spotlights menu.......................................................................................... 482 Economy menu............................................................................................. 483 9.1.16 Telescoping emergency program menu group.............................................................. 484 Telescoping emergency program menu....................................................................... 485 Unknown telescoping menu................................................................................. 486 9.1.17 Settings menu group................................................................................... 487 Crane cab menu........................................................................................... 488 Set display brightness and date/time menu................................................................ 489 Switch units menu........................................................................................ 490 Set control lever characteristic curve menu.............................................................. 491 Power unit speeds menu................................................................................... 492 9.1.18 Information menu group 2.............................................................................. 493 Operating hours menu..................................................................................... 494 Engine/transmission error menu........................................................................... 495 Crane operation error menu............................................................................... 496 Program version menu..................................................................................... 497 9.1.19 Various controls...................................................................................... 498 9.1.20 Query menus........................................................................................... 499 9.1.21 RCL control unit...................................................................................... 500 9.1.22 Menu-independent displays............................................................................. 501 9.1.23 RCL – menus........................................................................................... 502 Monitoring menu.......................................................................................... 502 Lifting capacity tables menu............................................................................. 504 Datalogger menu.......................................................................................... 505 9.1.24 Hand-held control..................................................................................... 506 9.1.25 Outrigger control units............................................................................... 507 Menu-independent buttons................................................................................. 507 Outrigger menu........................................................................................... 508 Raise axle menu.......................................................................................... 510 9.2 Short description of the operating elements.................................................................. 511 9.2.1 Definition of direction information.................................................................... 511 Basic rule............................................................................................... 511 9.2.2 General rules for buttons and symbols on the display................................................... 512 9.2.3 Engine................................................................................................. 513 Side panel............................................................................................... 513 Economy menu............................................................................................. 514 9.2.4 AdBlue (DEF) system/Exhaust gas emission control system................................................ 515 CCS display.............................................................................................. 515 9.2.5 Air intake inhibitor................................................................................... 517 9.2.6 Seat contact switch and dead man's switch.............................................................. 518 9.2.7 Crane control CCS...................................................................................... 519 9.2.8 Outrigger – crane cab.................................................................................. 524 Control panels........................................................................................... 524 CCS display.............................................................................................. 525 9.2.9 Outrigger control units................................................................................ 527 General information...................................................................................... 527 Outrigger menu........................................................................................... 528 9.2.10 Axle raising system................................................................................... 530 9.2.11 Inclination indicators................................................................................ 532 9.2.12 Outrigger pressure displays........................................................................... 533 Outrigger menu........................................................................................... 533 Outrigger control units.................................................................................. 533 9.2.13 Anemometer displays................................................................................... 533 9.2.14 Counterweight menu.................................................................................... 534 Counterweight submenu.................................................................................... 534 9.2.15 Main hoist............................................................................................ 538 Control panels........................................................................................... 538 CCS display.............................................................................................. 538 9.2.16 Auxiliary hoist....................................................................................... 540 Control panels........................................................................................... 540 CCS display.............................................................................................. 541 9.2.17 Slewing gear.......................................................................................... 542 Control panels........................................................................................... 542 CCS display.............................................................................................. 543 9.2.18 Derricking gear....................................................................................... 544 Control panels........................................................................................... 544 CCS display.............................................................................................. 545 Side panel............................................................................................... 545 9.2.19 Telescoping mechanism................................................................................. 546 Control panels........................................................................................... 546 Display CCS.............................................................................................. 546 Telescoping semi- automation menu........................................................................ 547 Manual telescoping menu.................................................................................. 549 9.2.20 Hydraulic system...................................................................................... 552 9.2.21 Superstructure lock menu.............................................................................. 553 Turntable lock........................................................................................... 553 Houselock................................................................................................ 555 9.2.22 Remote control........................................................................................ 556 9.2.23 Rated capacity limiter (RCL).......................................................................... 557 CCS display.............................................................................................. 557 RCL display.............................................................................................. 566 RCL override – version A................................................................................. 567 RCL override – version B................................................................................. 568 9.2.24 Electrical system..................................................................................... 569 9.2.25 Lighting, windscreen wiper/washing system............................................................. 570 Lighting................................................................................................. 570 Windscreen wiper/ washing system......................................................................... 572 Horn..................................................................................................... 573 9.2.26 Hand-held control..................................................................................... 574 Engine control panel..................................................................................... 574 Horn..................................................................................................... 574 Pre-selecting emergency operation........................................................................ 575 9.2.27 Windows and doors..................................................................................... 576 Windows.................................................................................................. 576 Rear window.............................................................................................. 576 Crane cab door........................................................................................... 577 9.2.28 Diagnostics........................................................................................... 578 9.2.29 Other................................................................................................. 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.................................................................... 580 10.2.1 Checking the fuel level and AdBlue (DEF) level........................................................ 580 Fuel..................................................................................................... 580 AdBlue (DEF)............................................................................................. 580 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 on the ignition............................................................................. 583 10.2.4 Control lever deflection query........................................................................ 584 10.2.5 Display – setting the brightness...................................................................... 585 10.2.6 Starting the engine................................................................................... 585 10.2.7 Checks after starting the engine...................................................................... 586 10.2.8 Setting idling speed.................................................................................. 587 10.3 Starting the engine – with the hand-held control............................................................ 588 Prerequisites................................................................................................ 588 Starting the engine.......................................................................................... 588 10.4 Switching off the engine.................................................................................... 589 10.4.1 Normally with the ignition lock / with the hand-held control.......................................... 589 After switching off...................................................................................... 589 10.4.2 Using the emergency stop switches..................................................................... 590 Resetting the emergency stop switch...................................................................... 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 Crane cab heater fuel tank............................................................................... 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 Control panels........................................................................................... 599 Front control panel...................................................................................... 599 11.1.4 Checking the safety devices........................................................................... 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 the hydraulic oil.......................................................................... 604 Prerequisites............................................................................................ 604 Preheating............................................................................................... 604 11.1.7 Locking/unlocking the turntable....................................................................... 605 Locking points........................................................................................... 605 Locking the turntable.................................................................................... 606 Unlocking the turntable.................................................................................. 606 11.1.8 Switching the houselock on/off........................................................................ 607 Switching on the houselock............................................................................... 607 Switching off the houselock.............................................................................. 609 11.1.9 Setting the time...................................................................................... 610 11.2 Standard slewing range type................................................................................. 611 11.2.1 Permissible slewing ranges and operating positions.................................................... 611 360° slewing range....................................................................................... 611 Operating 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.... 617 11.4 Operation of the rated capacity limiter..................................................................... 619 11.4.1 Switching on the RCL.................................................................................. 620 Switching on............................................................................................. 620 11.4.2 Entering the 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............................................................................. 631 11.4.4 Confirming the rigging mode and lifting capacity table................................................ 632 Slewing range type Standard.............................................................................. 632 MAXbase slewing range type............................................................................... 634 11.4.5 Checks before operating the crane..................................................................... 637 Monitoring menu.......................................................................................... 637 Checking the rigging mode................................................................................ 637 Hoist checks............................................................................................. 640 11.4.6 Displays during crane operation....................................................................... 641 On the RCL display....................................................................................... 641 On the CCS display....................................................................................... 645 11.4.7 RCL early warning..................................................................................... 649 11.4.8 RCL shutdown.......................................................................................... 649 Shutdown due to overload................................................................................. 649 11.4.9 Displaying the lifting capacity tables................................................................ 651 Standard slewing range type.............................................................................. 651 MAXbase slewing range type............................................................................... 653 11.4.10 RCL override – version A............................................................................. 655 Overview of status display............................................................................... 655 When rigging............................................................................................. 656 To raise the boom........................................................................................ 657 In emergencies........................................................................................... 658 11.4.11 RCL override – version B............................................................................. 659 11.4.12 Data logger.......................................................................................... 660 Exporting data........................................................................................... 660 Displaying the data...................................................................................... 661 11.5 Crane operation with main boom.............................................................................. 665 11.5.1 Checks during crane operation......................................................................... 665 Horizontal alignment..................................................................................... 665 Safe distances........................................................................................... 665 Checking the wind speed.................................................................................. 666 Deformation of the main boom due to direct sunlight...................................................... 667 11.5.2 Main hoist............................................................................................ 668 Switching on the main hoist.............................................................................. 669 Lifting and lowering..................................................................................... 670 Maximum permissible hoist rope speed..................................................................... 671 Switching off the main hoist............................................................................. 671 11.5.3 Auxiliary hoist....................................................................................... 672 Switching on the auxiliary hoist......................................................................... 672 Lifting and lowering..................................................................................... 673 Maximum permissible hoist rope speed..................................................................... 674 Switching off the auxiliary hoist........................................................................ 674 11.5.4 Lifting limit switch and lowering limit switch........................................................ 675 Lifting limit switch..................................................................................... 675 Lowering limit switch.................................................................................... 677 11.5.5 Derricking gear....................................................................................... 678 Switching on the derricking gear......................................................................... 678 Raising and lowering..................................................................................... 679 Maximum derricking speed................................................................................. 680 Re-enabling the raising function......................................................................... 680 Switching off the derricking gear........................................................................ 681 Lowering the main boom to a horizontal position.......................................................... 681 11.5.6 Telescoping mechanism................................................................................. 682 Overview................................................................................................. 683 Telescoping process...................................................................................... 684 Assignment for display................................................................................... 687 Fixed length, intermediate length, telescoping length.................................................... 688 Telescoping.............................................................................................. 689 Telescoping sequence..................................................................................... 689 Checks before starting work.............................................................................. 690 Switching on the telescoping mechanism................................................................... 691 Function of the control lever............................................................................ 691 Switching off the telescoping mechanism.................................................................. 694 Manual telescoping....................................................................................... 694 Checking the initial position............................................................................ 695 Unlocking the telescoping cylinder....................................................................... 696 Extending/ retracting the telescoping cylinder........................................................... 698 Lock telescoping cylinder................................................................................ 699 Unlocking the telescopic section......................................................................... 700 Telescoping the telescopic section....................................................................... 701 Locking the telescopic section........................................................................... 702 Before on-road driving................................................................................... 703 Telescoping with semi-automation......................................................................... 704 Telescoping with pre-selection........................................................................... 706 11.5.7 High-speed mode....................................................................................... 707 Derricking gear/ telescoping mechanism................................................................... 707 Hoists................................................................................................... 708 11.5.8 Slewing gear.......................................................................................... 709 Slewing gear brake....................................................................................... 709 Switching on the slewing gear............................................................................ 710 Releasing the slewing gear brake......................................................................... 710 Engaging the slewing gear brake.......................................................................... 710 Slewing.................................................................................................. 711 Maximum slewing speed.................................................................................... 712 Braking the slewing movement............................................................................. 713 Slewing gear freewheel................................................................................... 713 Switching off the slewing gear........................................................................... 714 11.5.9 Slewing speed – Switching the reduction on and off.................................................... 715 Switching reduction off.................................................................................. 715 11.5.10 Possible movement combinations....................................................................... 716 11.6 Settings and displays for crane operation................................................................... 717 11.6.1 Inclining the crane cab............................................................................... 717 11.6.2 Setting the idling speed.............................................................................. 718 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper........................................... 718 11.6.4 Limiting the power unit speeds........................................................................ 719 11.6.5 Setting/switching on Economy mode..................................................................... 720 Automatic................................................................................................ 720 Manual................................................................................................... 720 11.6.6 Switching the units of measure........................................................................ 721 11.6.7 Setting the characteristic curves for the control levers.............................................. 722 11.6.8 Using the slewable spotlights......................................................................... 723 Manually swinging........................................................................................ 724 Automatic load tracking.................................................................................. 724 11.6.9 Overriding torque reduction........................................................................... 725 11.6.10 Cleaning the exhaust system.......................................................................... 726 Automatic cleaning....................................................................................... 726 Manual cleaning.......................................................................................... 727 Disabling cleaning....................................................................................... 729 11.6.11 Displaying the operating hours....................................................................... 730 11.7 Working range limiter....................................................................................... 731 11.7.1 Viewing current settings.............................................................................. 732 On the RCL display....................................................................................... 732 In the CCS Start menu.................................................................................... 733 11.7.2 Opening the working range limiter menu................................................................ 733 11.7.3 Entering limit values – for the overall height........................................................ 734 11.7.4 Entering limit values – for the working radius........................................................ 736 11.7.5 Entering limit values – for the slewing range......................................................... 738 11.7.6 Entering limit values – for the hoist rope travel..................................................... 741 11.7.7 Shutdown by working range limiter..................................................................... 743 11.8 Work break.................................................................................................. 745 11.8.1 In case of short work breaks.......................................................................... 745 11.8.2 In case of work breaks longer than 8 hours............................................................ 746 Securing the truck crane................................................................................. 746 11.9 Heating and air-conditioning system......................................................................... 747 11.9.1 Heating system........................................................................................ 747 Switching on............................................................................................. 748 Heating.................................................................................................. 749 Air distribution......................................................................................... 750 Manually................................................................................................. 751 Automatically............................................................................................ 751 11.9.2 UniControl control unit............................................................................... 752 Setting the date and time................................................................................ 753 Saving automatic heating start........................................................................... 754 Error messages........................................................................................... 756 11.9.3 Air-conditioning system............................................................................... 757 Notes.................................................................................................... 757 Switching on............................................................................................. 759 Drying the air........................................................................................... 759 Switching off............................................................................................ 760 11.10 CraneSTAR system........................................................................................... 761 11.10.1 Overview............................................................................................. 761 11.10.2 Position of the components........................................................................... 761 12 Rigging work...................................................................................................... 763 12.1 Rigging work checklists for crane operation with the main boom.............................................. 763 12.1.1 CHECKLIST: Rigging.................................................................................... 763 12.1.2 CHECKLIST: Unrigging.................................................................................. 767 12.2 Selecting the suitable site................................................................................. 771 12.2.1 Determining the required load-bearing area............................................................ 771 12.2.2 Safe distance from slopes and pits.................................................................... 774 12.2.3 Earthing the truck crane.............................................................................. 775 12.2.4 Safe distance from overhead power lines............................................................... 776 12.3 Rigging work after driving with a dolly..................................................................... 779 12.3.1 Switching off the boom floating position.............................................................. 779 12.3.2 Switching off the slewing gear freewheel.............................................................. 780 Before slewing........................................................................................... 780 12.3.3 Switching off boom pre-tensioning..................................................................... 781 12.4 Connecting/disconnecting the hand-held control.............................................................. 783 12.5 Starting the engine for rigging............................................................................. 785 12.5.1 Starting/turning off the engine with the hand-held control............................................ 785 Prerequisites............................................................................................ 785 Starting the engine...................................................................................... 786 Switching off the engine................................................................................. 786 12.5.2 Starting/switching off the engine from the outrigger control units.................................... 787 Prerequisites............................................................................................ 787 Starting the engine...................................................................................... 787 Switching off the engine................................................................................. 787 12.6 Outriggers – Overview – Standard slewing range type......................................................... 789 12.6.1 Representation in the lifting capacity tables......................................................... 789 12.6.2 Enabled outrigger spans............................................................................... 790 12.7 Outriggers – Overview – MAXbase slewing range type.......................................................... 791 12.7.1 Definitions........................................................................................... 791 12.7.2 Representation in the lifting capacity tables......................................................... 793 12.7.3 Enabled outrigger spans............................................................................... 794 12.8 Operating the outriggers.................................................................................... 799 12.8.1 CHECKLIST: Extending the outriggers................................................................... 799 12.8.2 CHECKLIST: Retracting the outriggers.................................................................. 801 12.8.3 Preparing the truck crane............................................................................. 802 12.8.4 Setting the spans..................................................................................... 803 For on-road driving...................................................................................... 805 12.8.5 Extending/retracting outrigger beams.................................................................. 806 From the control units................................................................................... 807 From the crane cab....................................................................................... 808 12.8.6 Moving the outrigger pads into operating/driving position............................................. 810 12.8.7 Enlarging the load-bearing area....................................................................... 811 12.8.8 Extending/retracting supporting cylinders............................................................. 812 From the control units................................................................................... 813 From the crane cab....................................................................................... 814 12.8.9 Levelling the truck crane on outriggers horizontally.................................................. 816 Inclination indicators................................................................................... 816 Prerequisites............................................................................................ 817 Manual alignment......................................................................................... 818 Automatic alignment...................................................................................... 819 12.8.10 Operating the axle raising system.................................................................... 820 12.8.11 Outrigger pressure display........................................................................... 822 12.9 Rigging/unrigging the counterweight......................................................................... 825 12.9.1 Information on rigging................................................................................ 825 When rigging............................................................................................. 825 When unrigging........................................................................................... 826 12.9.2 Counterweight sections................................................................................ 827 Version 1................................................................................................ 827 Version 2................................................................................................ 827 12.9.3 Identification........................................................................................ 829 12.9.4 Slinging points on the counterweight sections......................................................... 830 12.9.5 CHECKLIST: Rigging the counterweight.................................................................. 833 12.9.6 CHECKLIST: Unrigging the counterweight................................................................ 834 12.9.7 Assembling counterweight combinations................................................................. 835 Version 1................................................................................................ 837 Version 2................................................................................................ 839 12.9.8 Counterweight hoist unit.............................................................................. 841 Counterweight menu....................................................................................... 841 Extending/retracting the lifting cylinders............................................................... 842 Automatic rigging........................................................................................ 843 Automatic unrigging...................................................................................... 845 Cancelling automatic mode................................................................................ 846 12.9.9 Setting down counterweight for driving the truck crane................................................ 847 12.9.10 Slewing with rigged counterweight.................................................................... 850 12.10 Rigging work on the main boom.............................................................................. 851 12.10.1 Hook block on the bumper............................................................................. 851 Picking up the hook block................................................................................ 851 Attaching the hook block................................................................................. 852 12.10.2 Hook block in the compartment........................................................................ 853 Prerequisites............................................................................................ 853 12.10.3 Hook block on a separate vehicle..................................................................... 855 Picking up the hook block................................................................................ 856 Setting down the hook block.............................................................................. 856 12.10.4 Hook block, separable................................................................................ 858 Rigging for on-road driving.............................................................................. 858 Rigging for crane operation.............................................................................. 859 12.10.5 Reeving and unreeving the hoist rope................................................................. 860 Reeving the hoist rope................................................................................... 862 Unreeving the hoist rope................................................................................. 865 12.10.6 Possible reeving methods on the main boom............................................................ 866 With 7 head sheaves...................................................................................... 866 With 10 head sheaves..................................................................................... 869 With 11 head sheaves..................................................................................... 872 12.10.7 Installing/removing the lifting limit switch......................................................... 873 Installing the lifting limit switch...................................................................... 873 Removing the lifting limit switch........................................................................ 876 12.10.8 Locking/unlocking the lifting limit switch........................................................... 878 Locking.................................................................................................. 878 Unlocking................................................................................................ 878 12.10.9 Anemometer and air traffic control light............................................................. 879 Installing............................................................................................... 879 Switching on/off......................................................................................... 880 Removing................................................................................................. 880 For transport............................................................................................ 881 12.11 Other rigging work......................................................................................... 883 12.11.1 Railings on the turntable............................................................................ 883 12.11.2 Folding the lighting carrier in/out.................................................................. 884 12.11.3 Safety harness on the main boom...................................................................... 885 Prerequisites............................................................................................ 886 Requirements............................................................................................. 886 Attaching/detaching fall prevention safety system to/ from safety harness................................ 887 Inspecting/replacing the safety harness.................................................................. 889 12.11.4 Slinging points for personal protective equipment.................................................... 890 12.11.5 Cameras for crane operation.......................................................................... 891 Camera on main boom...................................................................................... 891 Camera on the hoists..................................................................................... 894 Camera on the driver's cab............................................................................... 894 Operating the camera..................................................................................... 895 12.11.6 Step at the crane cab................................................................................ 897 12.11.7 Additional spotlights on the carrier and superstructure.............................................. 899 On the carrier........................................................................................... 899 On the superstructure.................................................................................... 900 12.11.8 Slinging points for personal protective equipment.................................................... 901 13 Driving with a rigged truck crane................................................................................. 903 13.1 Driving route............................................................................................... 903 13.2 Permissible rigging modes and axle loads.................................................................... 904 Axle load table.............................................................................................. 904 13.3 Before driving.............................................................................................. 907 13.3.1 Secure the superstructure against slewing............................................................. 907 13.3.2 Checking tyre pressure and wind speed................................................................. 908 13.3.3 Putting the truck crane on the wheels – with the Raise axle function.................................. 909 13.3.4 Putting the truck crane on the wheels – with the outriggers........................................... 911 13.3.5 Gears/connections..................................................................................... 913 Transmission............................................................................................. 913 Switching on separate steering........................................................................... 913 13.4 While driving............................................................................................... 915 13.5 After driving............................................................................................... 916 14 Malfunctions during crane operation............................................................................... 917 14.1 Emergency stop switch....................................................................................... 917 14.2 What to do when malfunctions occur during crane operation................................................... 918 The load can be set down..................................................................................... 918 Load cannot be set down...................................................................................... 918 14.3 Warning and error messages.................................................................................. 919 Program version.............................................................................................. 919 14.3.1 Warning messages on the CCS display................................................................... 919 14.3.2 Error messages on the CCS display..................................................................... 920 14.3.3 Warning messages on the RCL display................................................................... 922 14.4 Finding and eliminating malfunctions........................................................................ 929 14.4.1 Engine malfunctions................................................................................... 929 14.4.2 Malfunctions on the main hoist/auxiliary hoist........................................................ 929 14.4.3 Malfunctions in the hoist cameras..................................................................... 930 14.4.4 Malfunctions in the main boom camera.................................................................. 931 14.4.5 Malfunctions on the derricking gear................................................................... 932 14.4.6 Malfunctions in the telescoping mechanism............................................................. 933 14.4.7 Malfunctions on the slewing gear...................................................................... 935 14.4.8 Malfunctions on the counterweight hoist unit.......................................................... 936 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler............................................. 937 14.4.10 Malfunctions when operating with the hand-held control............................................... 937 14.4.11 Malfunctions when inclining the crane cab............................................................ 937 14.4.12 Malfunctions of the outriggers....................................................................... 938 14.4.13 Malfunctions when raising the axles.................................................................. 938 14.4.14 Malfunctions in the air-conditioning system.......................................................... 939 14.4.15 Malfunctions in the CCS/RCL control units............................................................ 939 14.4.16 Malfunctions on the CraneSTAR system................................................................. 939 14.5 Emergency operations and programs........................................................................... 941 14.5.1 Mechanical emergency activation for retracting........................................................ 942 Prior to the emergency activation, check................................................................. 942 Procedure................................................................................................ 942 Mechanical emergency activation.......................................................................... 943 14.5.2 Telescoping emergency program......................................................................... 945 Checks before using the emergency program................................................................ 945 Open submenu Emergency program........................................................................... 946 Determining the error type............................................................................... 947 In the case of an error at the length indicator.......................................................... 948 Tables for approaching the locking points................................................................ 952 14.5.3 Entering the current telescoping...................................................................... 955 14.5.4 Emergency operation with the hand-held control........................................................ 957 Preparations............................................................................................. 957 Operating a power unit................................................................................... 958 Stopping movements....................................................................................... 960 Stopping movements in emergencies........................................................................ 960 Switching off the engine................................................................................. 960 14.5.5 Notes on slewing in emergency operation............................................................... 961 For the standard slewing range type...................................................................... 961 For the MAXbase slewing range type....................................................................... 962 14.5.6 Slewing with an overridden slewing gear shutdown...................................................... 963 14.6 Hydraulic emergency operation with the hand pump............................................................ 964 14.6.1 Operating principle................................................................................... 964 14.6.2 Switching over the crane's hydraulic system........................................................... 965 14.6.3 Establishing the hydraulic circuits required.......................................................... 966 Releasing/ securing valves............................................................................... 966 Switching over valves.................................................................................... 967 For lowering............................................................................................. 968 14.6.4 Performing emergency activation....................................................................... 969 14.6.5 After the emergency activation........................................................................ 970 14.7 Hydraulic emergency operation............................................................................... 971 14.7.1 Operating principle................................................................................... 971 14.7.2 Establishing the hydraulic circuits required.......................................................... 972 Switching over valves.................................................................................... 972 Switching continuous operation on and off................................................................ 973 14.7.3 Connecting/disconnecting the energy source............................................................ 974 14.7.4 Carrying out emergency operation...................................................................... 974 14.7.5 After emergency operation............................................................................. 974 14.8 Hydraulic emergency operation as per DGUV................................................................... 975 14.8.1 DGUV emergency operation operating principle.......................................................... 975 14.8.2 Connecting/disconnecting hoses........................................................................ 976 Establishing connections................................................................................. 976 Disconnecting connections................................................................................ 977 14.8.3 Switching emergency operation on/off.................................................................. 978 14.8.4 Establishing the hydraulic circuits required.......................................................... 979 Switching over valves.................................................................................... 979 For lifting/ lowering.................................................................................... 981 For slewing.............................................................................................. 982 14.8.5 Carrying out emergency operation...................................................................... 983 Slewing.................................................................................................. 983 Derricking............................................................................................... 984 Lifting/lowering......................................................................................... 984 14.8.6 After emergency operation............................................................................. 985 Switching off emergency operation........................................................................ 985 Switching over to crane operation........................................................................ 985 Disconnecting the hoses.................................................................................. 985 14.8.7 Emergency supply of another crane..................................................................... 986 For emergency supply..................................................................................... 986 After emergency supply................................................................................... 986 14.9 Fuses in the crane cab...................................................................................... 987 Notes on changing fuses...................................................................................... 987 Index.................................................................................................................... 993 A.................................................................................................................... 995 B.................................................................................................................... 995 C.................................................................................................................... 996 D.................................................................................................................... 999 E....................................................................................................................1000 F....................................................................................................................1002 H....................................................................................................................1002 I....................................................................................................................1004 K....................................................................................................................1004 L....................................................................................................................1004 M....................................................................................................................1005 O....................................................................................................................1006 P....................................................................................................................1007 R....................................................................................................................1007 S....................................................................................................................1009 T....................................................................................................................1010 W....................................................................................................................1012
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