Manitowoc Grove GMK5150L Crane Operator Manual PDF

Description

Manitowoc GROVE Crane GMK5150L Operating Instructions Manual 3302556  – PDF DOWNLOAD

FILE DETAILS:

Manitowoc GROVE Crane GMK5150L Operating Instructions Manual 3302556  – PDF DOWNLOAD

Language : English
Pages :982
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc GROVE Crane GMK5150L Operating Instructions Manual 3302556  – PDF DOWNLOAD

Additional page 5
Driving with a rigged crane 3
Permissible axle loads 3
Secure the superstructure against slewing 3
CCS – Datalogger 5
Additional menu and program 5
CCS display 11
Menu changes 11
Reduction of slewing speed – can be switchedon and off 15
Dimensions and weights of removable parts 19
Main boom 19
1 Overview 25
1 1 Accidents 25
1 2 Branch offices 27
1 2 1 Manitowoc Crane Care 27
1 2 2 Dealer list 27
1 3 Warranty specifications 27
1 4 Terms used 28
1 5 Technical data 31
1 5 1 Maximum lifting capacity (DIN/ISO/EN) 31
1 5 2 Dimensions and weights of the truck crane, axle loads 32
Dimensions 33
Weight and axleloads 33
1 5 3 Dimensions and weights of removable parts 34
Spare wheel 34
Outrigger 34
Hook blocks and hook tackle 34
Counterweight parts 35
1 5 4 Carrier 36
Engine 36
Transmission 36
Transfer case 36
Axle lines 36
Steering 36
Tyres 37
Outrigger 38
Electrical system 39
Tool 39
Towing coupling 39
Driving speeds 39
Climbing ability 39
Turning radii 40
1 5 5 Superstructure 40
Main hoist 40
Auxiliary hoist 41
Slewing gear 41
Derricking gear 41
Main boom 41
Lattice extension 41
Operating speeds 42
1 6 Documentation supplied 43
1 6 1 Questions on documentation 44
1 7 Notes on the operating manual 45
1 7 1 What do the symbols used mean? 45
1 7 2 How is the operating manual structured? 47
Division 47
Structure of thechapters 47
Structure of thepages 48
1 7 3 How do I find the information I need? 49
Cross-references example 50
1 7 4 What information is available for operations planning? 52
1 8 Conversion table for US measuring units 53
1 9 Training – Information 55
1 10 Identification 56
1 11 EC Declaration of Conformity 58
2 Basic safety instructions 61
2 1 Intended use 61
2 1 1 Improper use 62
2 2 Organisational measures 63
2 3 Personnel qualifications 65
2 4 Safety instructions for driving the truck crane 67
2 5 Safety instructions for crane operation 69
2 6 Instructions on transporting persons 73
Equipment for lifting persons 73
Personnel 74
Operation 74
Truck crane 75
3 Operating elements for driving 79
3 1 Overview of the operating elements 79
3 1 1 Exterior of the truck crane 80
3 1 2 Driver’s cab 84
Front overview 84
Rear overview 86
Behind the cover 87
3 1 3 Steering column/steering wheel 89
3 1 4 Instrument panel 91
Left/right 91
Middle 92
3 1 5 Transmission operating elements 94
3 1 6 On-board computer 95
3 1 7 Tachograph, on-board computer time correction 96
3 1 8 Heating and air-conditioning system 97
Standard 97
Auxiliary water heating system 98
Auxiliary air heater 99
3 1 9 CCS control unit 100
3 1 10 CCS display – Start menu 101
3 1 11 CCS – Overview menu groups 102
Carrier menu group 104
Suspension/level adjustment menu 105
Driving menu 106
Settings menu group 107
Menu for setting the display brightness anddate/time 108
Switch units menu 109
Information menu group 110
Operating hours menu 111
Engine/transmission error menu 112
Crane operation error menu 113
Operating additional equipment 114
Emergency operation 115
3 1 12 Outriggers control units 116
3 2 Brief description of the operating elements 117
3 2 1 Definition of direction references 117
Basic rule 117
Switches and buttons 118
3 2 2 General rules for buttons and symbols on the display 118
3 2 3 Crane control CCS 119
3 2 4 Engine 124
Steering column 124
On the steering wheel 124
Instrument panel 125
3 2 5 AdBlue system 126
Instrument panel 126
CCS display 127
3 2 6 Battery master switch 127
3 2 7 Electrical system 128
3 2 8 Transmission 129
Transmission control unit 129
Display driving mode 131
3 2 9 Reverse camera 132
3 2 10 BirdView system 270 133
3 2 11 Transfer case 135
3 2 12 Final drive 136
3 2 13 Brakes 138
Service brake 138
Parking brake 138
Additional brakes 139
3 2 14 Steering / separate steering 140
Instrument panel 140
CCS display 142
3 2 15 Suspension 144
CCS display 144
Outriggers control units 144
3 2 16 Lighting/windscreen wipers/horn 145
Steering column 145
Steering wheel 145
Instrument panel 145
CCS display 147
Roof 147
3 2 17 Level adjustment system 148
3 2 18 Tachograph/speedometer 150
Tachograph 150
Speedometer 150
3 2 19 Diagnostics 151
3 2 20 On-board computer 152
3 2 21 Push-up roof 153
3 2 22 Windows and doors 154
Window winder 154
Doors 155
3 2 23 Front flap 156
4 Starting/switching off the engine – for driving 159
4 1 Starting the engine from the driver’s cab 159
4 1 1 CHECKLIST: Starting the engine 159
4 1 2 CHECKLIST: At low temperatures 162
4 1 3 Ladders 163
Folding ladder 164
4 1 4 Refuelling 165
Fuel tank 165
AdBlue tank 167
4 1 5 Checks before starting the engine 168
At the hydraulic tank 168
Battery master switch 169
Checking the hand-held control 169
4 1 6 Switching on the ignition 169
4 1 7 Lamp test/equalisation of the switching states 170
Lamp test 170
Alignment of theswitching statuses 170
4 1 8 Display brightness 171
4 1 9 Start the engine 172
4 1 10 Inspections after starting the engine 174
Main menu and on-board computer display 174
Instrument panel 175
4 1 11 Adjust idling speed 177
4 2 Switching off the engine 179
4 2 1 At the ignition lock and with the outrigger control units 179
After turning off 179
4 2 2 With emergency stop switches 180
Resetting the emergency stop switch 180
4 3 Air intake inhibitor 181
Releasing the air intake inhibitor 181
5 Driving mode 185
5 1 Before driving 185
5 1 1 CHECKLIST: Checks before on-road driving 185
5 1 2 Checking the condition of the truck crane 191
Electrical system 191
Adjust the mirrors 191
Warning plates for vehicle width 192
Displaying vehicle height 193
Supply pressure 194
Parking brake 195
5 1 3 Adjusting the seats and steering column 197
Adjusting the driver’s seat 197
Adjusting the passenger’s seat 198
Steering column, adjusting 199
5 1 4 Switching the suspension on/off 200
Open menu 200
Switching the suspension on 201
Switching off the suspension 201
5 1 5 Setting the tachograph 202
Prerequisites 202
In the event of malfunctions 202
Setting the tachograph 203
5 1 6 Entering the time/date 207
5 1 7 Displaying and resetting operating hours 208
5 2 Operating the transmission 209
5 2 1 Switching on 209
5 2 2 Switching the transmission to the neutral position 210
5 2 3 Selecting the direction of travel and starting gear 211
Selecting the driving direction 211
Selecting the starting gear  212
5 2 4 Changing the operating mode 213
Changing to automatic mode 213
Changing to manual mode 213
5 2 5 Starting 214
5 2 6 Driving and changing gears 215
In automatic operating mode 215
In manual operating mode 216
5 2 7 Changing the driving direction 217
5 2 8 Stopping 217
Stopping for a long period of time 217
5 2 9 On the roller type dynamometer 218
5 2 10 Preheating transmission 218
5 3 Driving and turning off the truck crane 219
5 3 1 Checks while driving 219
Immediately after you start to move 219
While driving 221
5 3 2 Cruise control 222
Switching on 222
Switching off 223
5 3 3 Temposet 223
Switching on 223
Switching off 224
5 3 4 Driving downhill 225
Starting 225
Inspections when driving downhill 226
Downshifting 226
Additional brakes 227
5 3 5 Driving uphill 229
Starting 229
Driving 229
5 3 6 Warning or malfunction messages on the instrument panel 230
Meaning of thelamps 230
5 3 7 Messages on the on-board computer display 231
5 3 8 Indicator lights in the on-board computer display 233
5 3 9 Overriding the torque reduction 235
5 3 10 Warnings in the start menu 236
5 3 11 Switching the truck crane off 237
Secure it against rolling away 238
When stationary for more than 8hours 239
5 3 12 Fold-up berth 240
5 4 Off-road driving 241
Adjustments to the transmission 241
Connections 241
Changing the vehicle level 241
Rocking the vehicle free and towing 241
5 4 1 Transfer case – switching the off-road gear on/off 242
Neutral position 242
5 4 2 Longitudinal and transverse differential locks 243
5 4 3 Operating the level adjustment system 245
Open menu 245
Setting the on-road level 246
Pre-selecting suspension struts 246
Changing the vehicle level 247
Viewing the current inclination 247
Exiting the menu 248
5 4 4 Freeing an immobilized truck crane 249
Rocking the truck crane free 249
Towing free to thefront 250
Towing free in reverse gear 250
5 5 Separate steering 251
5 5 1 Switching to separate steering 252
5 5 2 Switching to normal steering mode 255
5 5 3 Switching units of measure 256
5 6 Heating and air-conditioning system 257
5 6 1 Standard heating system 257
Switching on 257
Heating 257
Air distribution 258
Examples 260
Switching off 260
5 6 2 Air-conditioning system 261
Information 261
Switching on/off 261
Cooling 262
Drying 262
5 6 3 Auxiliary water heating system 264
Preheating theengine 264
Preheating the driver’s cab 265
Switching on 265
Adjusting thedateand time 267
Storing the heating start 268
5 6 4 Auxiliary air heater 270
Switching on 270
Setting the heating level 271
Setting the day and time 272
Setting the preselection time 272
Deleting preselection times 274
Switching off 274
5 7 Towing a trailer 276
Effects on the axleloads 276
Coupling thetrailer 277
Connecting the supply lines 278
Removing supplylines 279
Uncoupling thetrailer 279
Checking the braking force 281
6 Driving modes 285
6 1 Driving modes 285
Information on the axle loads 285
6 1 1 How to use the tables: 286
6 1 2 Table for a maximum axle load of 12 t 287
385/95 R25 tyres 287
445/95 R25 tyres 288
525/80 R25 tyres 289
6 1 3 Maximum permitted speeds with an axle load of over 12 t 290
6 2 Weighing the truck crane 291
Axle groups 292
Weighing procedure 293
Evaluation 294
6 3 Rigging work for driving with a trailer 295
6 3 1 Switching on the slewing gear freewheel 296
6 3 2 Switching on the boom floating position 297
6 3 3 Switching on boom pre-tensioning 298
6 3 4 Raising/lowering the 3rd axle line for towing a trailer 299
Lifting 299
Lowering 299
6 4 Rigging the main boom 301
Additional equipment required 301
6 4 1 CHECKLIST: removing the main boom 302
Prerequisites 302
Checklist 302
6 4 2 CHECKLIST: installing the main boom 305
Prerequisites 305
Checklist 305
6 4 3 Slinging the main boom 308
Marking 308
Installing the lifting gear 308
Removing the lifting gear 309
6 4 4 Switching the pressure relief on/off 310
6 4 5 Retracting/fitting the derricking cylinder head pin 311
Retracting the derricking cylinder head axle 312
Fitting the derricking cylinder head axle 313
6 4 6 Extending/retracting the boom pivot pin 314
Before pulling itout 314
After pushing it in 314
Pulling out the pivot pin 315
Pushing the pivotpin in 316
6 4 7 Removing/attaching the clamps 318
6 4 8 Disconnecting/connecting hydraulics/electrical 319
Disconnecting 319
Connecting 320
6 4 9 Aligning the connecting points 321
6 4 10 Securing/releasing the derricking cylinder 322
6 4 11 Transporting the main boom 322
6 4 12 Inspections after main boom mounting 323
6 5 Installing/removing the auxiliary hoist 325
6 5 1 Slinging the auxiliary hoist 325
6 5 2 CHECKLIST: Installing the auxiliary hoist 326
6 5 3 CHECKLIST: Removing the auxiliary hoist 327
6 5 4 Making/breaking the connection between the auxiliary hoist and the turntable 328
6 5 5 Establishing/disconnecting the hydraulic connection 329
6 5 6 Establishing/disconnecting the electrical connection 330
6 5 7 Making/breaking the connection to the central lubrication 331
6 5 8 Transporting the auxiliary hoist 332
6 5 9 Check that the auxiliary hoist is functioning properly 333
Slewing direction 333
Slewing indicator 333
7 Transport 337
7 1 Transport with transport vehicle 337
7 1 1 CHECKLIST: Checks before transport 338
7 1 2 Drive the truck crane on to the transport vehicle 340
Driving on 341
Lashing 341
7 2 Transport by ship 342
8 Malfunctions in driving mode 345
8 1 Emergency stop switches 345
8 2 What to do when a malfunction occurs in road traffic 347
8 3 Towing away the truck crane 349
8 3 1 Towing after engine/transmission damage 350
Compressed-air supply 350
Electric power supply 350
On the transmission 351
Axle drives 351
Parking brake 352
Towing the truck crane out of the danger area 353
Longer towing distances 353
8 3 2 Tow starting 353
8 4 Other emergency operations 355
8 4 1 Externally starting the truck crane 355
8 4 2 Battery charger 356
Prerequisites 356
8 5 Wheels and tyres 357
8 5 1 Wheel change 357
Removing a damaged wheel 358
On the spare wheel holder 358
Mounting a wheel 359
8 5 2 Inflating the tyres yourself 361
Connecting the filling hose 361
Inflating the tyres 362
Remove the fillinghose 362
8 6 Tilting/lowering the driver’s cab 363
8 6 1 Prerequisites and information on tilting 363
8 6 2 Tilting/lowering the driver’s cab 364
Operating the hand pump 364
Tilting the driver’scab 365
Lowering the driver’s cab 366
8 7 Fuses on the carrier 369
Information on replacing fuses 369
8 7 1 Fuses in the driver’s cab 370
8 7 2 Fuses in the battery box 376
8 8 Troubleshooting 377
8 8 1 Malfunctions on the engine 377
When operating with the dual tank 379
8 8 2 Faults on the Adblue system 379
8 8 3 Malfunctions of the differential locks 380
8 8 4 Malfunctions in the transmission 381
8 8 5 Malfunctions of the steering 382
8 8 6 Malfunctions of the service brake 383
8 8 7 Malfunctions on the suspension 384
8 8 8 Malfunctions of the level adjustment system 384
8 8 9 Malfunctions in the hydraulic system/hydraulic oil cooler 384
8 9 CCS warning/error message 385
Symbols in the display area 385
8 9 1 Engine/transmission error menu 389
Open menu 389
Exiting the menu 389
8 10 Procedure during malfunctions 391
8 10 1 Procedure during engine malfunctions 391
8 10 2 Procedure during transmission malfunctions 392
9 Operating elements for crane operation 397
9 1 Overview of the operating elements 397
9 1 1 Exterior of the truck crane 398
9 1 2 Crane cab 402
Side panel 404
Crane cab, rear 406
9 1 3 Control panels 408
Left 408
Right 409
9 1 4 Control lever configuration 410
Version 1 410
Version 2 411
9 1 5 CCS control unit 412
9 1 6 CCS – Start menu 415
9 1 7 CCS – Overview menu groups 416
Superstructure menu group 420
Superstructure lock sub-menu 421
Counterweight menu 422
Outrigger menu 423
Outrigger support beam menu 425
Outrigger cylinders menu 426
Menu group Teleautomation 428
Telescoping full automation menu 429
Telescoping semi- automation menu 430
Manual telescoping menu 431
Main boom configuration menu 432
Active working range limiter menu group 433
Overall height menu 434
Working radius menu 435
Slewing angle menu 436
Hoist rope travel limitation menu 437
Information menugroup 438
Hydraulic pressure and fuel consumption menu 439
Engine/Driving menu group 441
Driving mode menu 442
Economy mode menu 444
Remote control menu 445
Heating/air-conditioning menu 446
Spotlights menu 447
Telescoping emergency program menu group 448
Unknown telescoping menu 449
Telescoping emergency program menu 450
Settings menu group 451
Crane cab menu 452
Menu for setting the display brightness and date/ time 453
Switch units menu 454
Set control lever characteristic curve menu 455
Power unit speeds menu 456
Information menu group 457
Operating hours menu 458
Engine/transmission error menu 459
Crane operation error menu 460
Program version menu 461
Operating additional equipment 462
9 1 8 RCL control unit 463
9 1 9 RCL – menu groups 466
Enter rigging mode menu 468
Monitoring menu 469
Lifting capacity table menu 470
9 1 10 Hand-held control 471
9 1 11 Outriggers control units 472
Button 472
Outrigger button 473
Inclination and outrigger pressure display 474
Raise axle display 475
9 2 Brief description of the operating elements 477
9 2 1 Definition of direction references 477
Basic rule 477
Switches 477
9 2 2 General rules for buttons and symbols on the display 478
9 2 3 Crane control CCS 479
9 2 4 Engine 486
Side panel 486
CCS display 486
Economy mode menu 487
Left control lever 487
9 2 5 AdBlue system 488
CCS display 488
9 2 6 Seat contact switch and dead man’s switch 489
9 2 7 Outrigger 491
Right-hand control panel 491
Left-hand controlpanel 491
In the Outrigger menu 492
At the outrigger control units 495
9 2 8 Inclination indicators 497
9 2 9 Raise axle 498
Outriggers control units 498
CCS display 499
9 2 10 Outrigger pressure displays 500
Outrigger submenu 500
Outriggers controlunits 500
9 2 11 Anemometer displays 500
9 2 12 Counterweight menu 502
Counterweight submenu 502
9 2 13 Main hoist 506
Control panels 506
CCS display 506
9 2 14 Auxiliary hoist 508
Control panels 508
CCS display 508
9 2 15 Slewing gear 510
Control panels 510
CCS display 511
9 2 16 Derricking gear 512
Control panels 512
CCS display 513
9 2 17 Telescoping mechanism 514
Control panels 514
CCS display 514
Telescoping full automation menu 515
Telescoping semi- automation menu 516
Manual telescoping menu 518
Main boom configuration menu 521
9 2 18 Hydraulic system 522
9 2 19 Superstructure lock/house lock menu 523
Superstructure lock 523
Houselock 524
9 2 20 Remote control 525
9 2 21 Rated capacity limiter (RCL) 526
Control unit control console RCL 526
Display RCL 527
Enter rigging mode menu 528
Monitoring menu 532
Lifting capacity tables menu 536
RCL override – version A 537
RCL override – Version B 538
9 2 22 Electrical system 539
9 2 23 Lighting, windscreen wiper/washing system 540
Lighting 540
Windscreen wiper/washing system 542
9 2 24 Hand-held control 544
Sockets for hand-held control 544
Engine control panel 545
Horn 545
Outriggers control panel 546
9 2 25 Windows and doors 548
Windows 548
Rear window 548
Crane cab door 549
9 2 26 Diagnostics 550
9 3 Short description of the operating elements – driving from the crane cab 551
9 3 1 Driving mode menu 551
9 3 2 Transmission 552
9 3 3 Final drive 553
9 3 4 Brakes 554
CCS display 554
Side panel from above 555
9 3 5 Steering 556
CCS display 556
Separate steering 557
Control panels 559
10 Starting/switching off the engine – for crane operation 563
10 1 When starting the engine for the first time in the day 563
10 2 Starting the engine – from the crane cab 565
10 2 1 Check the fuel level and AdBlue level 565
Fuel 565
AdBlue 565
10 2 2 Checks before starting the engine 566
Checks on thecarrier 566
Checking the hand-held control 566
At the hydraulic tank 566
10 2 3 Switching on the ignition 567
10 2 4 Alignment of the switching statuses 568
Alignment of theswitching statuses 568
10 2 5 Display – setting the brightness 569
10 2 6 Start the engine 570
10 2 7 Inspections after starting the engine 571
10 2 8 Adjust idling speed 572
10 3 Starting the engine – with the hand-held control 573
10 4 Switching off the engine 575
10 4 1 At the ignition lock and with hand-held control 575
After turning off 575
10 4 2 With the idling button 575
10 4 3 Using the emergency stop switches 576
Resetting the emergency stop switch 576
11 Crane operation 579
11 1 Before operating the crane 579
11 1 1 CHECKLIST: Checks before operating the crane 579
11 1 2 Checking the condition of the truck crane 583
Fuel tank auxiliary heater 583
Visual inspection 583
Checking the position of the hoist ropes 584
Checking the electrical system 585
11 1 3 Adjusting the crane cab seat and front control panel 586
Crane cab seat 586
Front panel 587
11 1 4 Checking the safety equipment 588
Rated capacity limiter 588
Lifting limit switch 588
Emergency stop switches 589
Seat contact switch 590
11 1 5 Earthing the load 591
11 1 6 Preheating the hydraulic oil 592
Prerequisites 592
Preheating 592
11 1 7 Locking/unlocking the superstructure 593
Locking points 593
Locking the superstructure 594
Unlocking the superstructure 594
11 1 8 Switching the houselock on/off 595
Switching on the houselock 595
Switching off the houselock 597
11 2 Operation of the rated capacity limiter 599
11 2 1 Switch on the RCL 600
Switching on 600
Brightness of thedisplays 602
Temperature on the display 602
11 2 2 Enter rigging mode 603
Entering individual components 604
Entering the RCLcode 609
Enter the reeving 610
Accepting the rigging mode 610
11 2 3 Checks before operating the crane 612
Open menu 612
Checks 612
11 2 4 Displays during crane operation 615
11 2 5 RCL early warning 618
11 2 6 RCL shutdown 618
Shutdown due tooverload 618
11 2 7 Display in the event of errors 620
11 2 8 RCL override – version A 621
Overview status display 621
When rigging 622
To raise the boom 623
In emergencies 624
11 2 9 RCL override – version B 625
11 2 10 Displaying the lifting capacity tables 626
11 2 11 Setting the time/date 628
11 3 Crane operation with main boom 629
11 3 1 Checks during crane operation 629
Horizontal alignment 629
Safe distances 629
Checking the windspeed 630
11 3 2 Permissible slewing ranges and working positions 631
360 slewing range 631
Working position 0 to the rear 631
180 to the front rigging position 631
11 3 3 Main hoist 633
Switching on the main hoist 634
Lifting and lowering 634
Maximum permissible hoist rope speed 634
Switching off the main hoist 635
11 3 4 Auxiliary hoist 637
Switching on the auxiliary hoist 637
Lifting and lowering 638
Maximum permissible hoist rope speed 638
Switching off the auxiliary hoist 639
11 3 5 Lifting limit switch and lowering limit switch 641
Lifting limit switch 641
Lowering limit switch 643
11 3 6 Derricking gear 644
Switching on the derricking gear 644
Maximum permissible derricking speed 644
Raising and lowering 645
Re-enable raising function 646
Switching off the derricking gear 646
11 3 7 Telescoping mechanism 648
Overview 649
Telescoping process 650
Assignment fordisplay 652
Fixed length, intermediate length, telescoping length 653
Telescoping 654
Telescoping sequence 654
Checks before starting work 655
Switching on thetelescoping mechanism 656
Function of the control lever 656
Switching off thetelescoping mechanism 658
Manual telescoping 659
Checking the initial position 659
Unlocking the telescoping cylinder 661
Extending/ retracting the telescoping cylinder 663
Locking the telescoping cylinder 664
Unlocking the telescopic section 665
Telescoping the telescopic section 666
Locking the telescopic section 667
Locking the telescopic section for on-road driving 668
Telescoping with semi-automaton 668
Telescoping with full automation 671
Telescoping withmain boom configuration 672
11 3 8 High-speed mode 673
Derricking gear telescoping mechanism 673
Hoists 673
11 3 9 Slewing gear 675
Switching on the slewing gear 675
Releasing the slewing gear brake 675
Applying the slewing gear brake 676
Slewing 676
Releasing locked slewing gear 676
Maximum permitted slewing speed 677
Braking the slewing movement 678
Slewing gear freewheel 678
Switching off the slewing gear 679
11 3 10 Possible movement combinations 680
11 4 Settings and displays for crane operation 681
11 4 1 Inclining the crane cab 681
11 4 2 Adjust idling speed 682
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 682
11 4 4 Limiting the power unit speeds 683
11 4 5 Economy mode 684
Switching on 684
Switch off/exit 686
11 4 6 Switching units of measure 687
11 4 7 Setting the characteristic curves for the control levers 688
11 4 8 Using the slewable spotlights 689
Manually swinging 689
Automatic load tracking 690
11 4 9 Overriding the torque reduction 691
11 4 10 Displaying the operating hours 692
11 4 11 Warnings in the start menu 694
Meaning of the symbols 694
11 5 Working range limiter 698
11 5 1 Viewing current settings 699
11 5 2 Opening the working range limiter menu 699
11 5 3 Entering limit values 702
Overall height 702
Working radius 703
Slewing angle 703
Hoist rope travel limitation 704
11 5 4 Entering limit values manually 705
Limit values 705
11 5 5 Switching monitoring functions on/off 707
11 5 6 Shutdown by working range limiter 708
11 6 Work break 709
11 6 1 In case of short work breaks 709
11 6 2 In case of work breaks of more than 8 hours 710
To secure the truck crane 710
11 7 Heating and air-conditioning system 711
11 7 1 Standard heating system 711
Switching on 711
Heating 711
Air distribution 712
Switching off 712
11 7 2 Air-conditioning system 713
Information 713
Switching on/off 713
Cooling, automatic 714
Cooling, maximum 714
11 7 3 Auxiliary heater 715
Switching on 715
Adjusting the temperature 716
Setting the heating start/ heating duration 716
Switching heating start on/off 717
11 8 CraneSTAR system 718
11 8 1 Overview 718
11 8 2 Position of the components 718
12 Rigging work 721
12 1 Rigging work checklists for crane operation with the main boom 721
12 1 1 CHECKLIST: Rigging 721
12 1 2 CHECKLIST: Unrigging 727
12 2 Selecting the suitable site 731
12 2 1 Determining the required load-bearing area 731
12 2 2 Safe distance from slopes and pits 734
12 2 3 Earthing the truck crane 735
12 2 4 Safe distance from overhead power lines 736
12 3 Rigging work after driving with a trailer 739
12 3 1 Switching off the boom floating position 739
12 3 2 Switching off the slewing gear freewheel 740
Before slewing 740
12 3 3 Switching off boom pre-tensioning 741
12 4 Connecting/disconnecting the hand-held control 743
12 5 Starting the engine for rigging 745
12 5 1 Starting/turning off the engine with the hand-held control 745
Prerequisites 745
Start the engine 746
Switching off theengine 746
12 5 2 Starting/switching off the engine from the outrigger control units 747
Prerequisites 747
Start the engine 747
Switching off theengine 747
12 6 Outrigger 749
12 6 1 CHECKLIST: Extending the outriggers 749
12 6 2 CHECKLIST: Retracting the outriggers 751
12 6 3 Permissible outrigger spans 752
12 6 4 Preparing the truck crane 753
Driver’s cab 753
Crane cab 753
12 6 5 Setting the spans 755
For on-road driving 757
12 6 6 Extending/retracting outrigger beams 759
From the control units 760
From the cranecab 761
12 6 7 Moving the outrigger pads into operating/driving position 763
12 6 8 Enlarging the load-bearing area 765
12 6 9 Extending/retracting supporting cylinders 766
From the controlunits 767
From the cranecab 768
12 6 10 Levelling the truck crane on outriggers 770
Inclination indicators 770
Prerequisites 771
Manual alignment 772
Automatic alignment 773
12 6 11 Levelling the free-on-wheels truck crane 774
12 6 12 Outrigger pressure display 776
12 7 Rigging/unrigging the counterweight 777
12 7 1 Information on rigging 777
When rigging 778
When unrigging 779
12 7 2 Counterweight sections 780
Version 1 780
Version 2 780
Version 3 781
12 7 3 Identification 782
12 7 4 Slinging points on the counterweight sections 783
12 7 5 CHECKLIST: Rigging the counterweight 785
12 7 6 CHECKLIST: Unrigging the counterweight 787
12 7 7 Assembling counterweight versions 789
Setting down the 2 3 t base plate 790
Setting down the top counterweight section 790
Version 1 791
Version 2 799
Version 3 803
12 7 8 Counterweight hoist unit 811
Counterweight menu 811
Extending/ retracting the lifting cylinders 812
Automatic moderigging 814
Automatic mode unrigging 816
Cancel automatic mode 817
12 7 9 Removing/installing the counterweight on the turntable 818
Removing 818
Installing 819
12 7 10 Setting down counterweight for driving the truck crane 820
Version 1 and 3 820
Version 2 822
12 7 11 Slewing with the rigged counterweight 823
12 8 Rigging work on the main boom 825
12 8 1 Hook block on the bumper 825
Picking up the hook block 825
Attaching the hook block 826
12 8 2 Hook block on a separate vehicle 827
Picking up the hook block 828
Setting down the hook block 828
12 8 3 Hook block, separable 830
Rigging for on-road driving 830
Rigging for crane operation 831
12 8 4 Reeving and unreeving the hoist rope 832
Version A 832
Version B 833
Reeving the hoist rope 835
Unreeving hoist rope 839
12 8 5 Possible reeving methods on the main boom 840
With 6 head sheaves 840
With 8 head sheaves 842
With 9 head sheaves 846
12 8 6 Installing/removing the lifting limit switch 847
Installing lifting limit switch 847
Removing the lifting limit switch 850
12 8 7 Locking/unlocking the lifting limit switch 852
Locking 852
Unlocking 852
12 8 8 Anemometer and air traffic control light 853
Installing 853
Switching the air traffic control light on and off 854
Removing 854
12 9 Other rigging works 857
12 9 1 Folding the mirrors in and out, and adjusting them 857
12 9 2 Cameras for crane operation 858
Camera on mainboom 858
Camera on thehoists 860
Camera on the driver’s cab 860
Operating the camera 861
12 9 3 Railings on the turntable 862
12 9 4 Step for the crane cab 863
12 9 5 Slinging points for personal protective equipment 864
13 Driving with a rigged truck crane 867
13 1 Driving path 867
13 2 Permissible rigging modes and axle loads 868
Axle load table 869
13 2 1 To drive without a load 870
13 2 2 To drive with a load 871
13 2 3 Axle loads 871
13 3 Before driving the rigged truck crane 872
13 3 1 Check the tyre pressures and wind speed 872
13 3 2 Securing the superstructure against slewing 872
13 3 3 Putting the truck crane on the wheels 873
13 4 Driving from the driver’s cab 876
13 4 1 Preparing to drive 876
Transmission 876
Switching on separate steering 876
Connections 876
13 4 2 While driving 877
13 4 3 After driving 878
13 5 Driving from the crane cab 879
13 5 1 Preparing to drive 880
13 5 2 Opening/closing the Driving menu 880
Opening 880
Crane hydraulic system on/off 881
Closing 882
13 5 3 Steering 883
Switching on 883
Steering direction 883
Displays when steering 884
Separate steering 884
Normal steering mode 888
13 5 4 Operating the transmission 889
Selecting the transmission mode 889
13 5 5 While driving 890
DMand RM transmission mode 890
Transmission mode D 890
Warning messages 890
13 5 6 Possible connections 891
Longitudinal/ transverse differential locks 891
13 5 7 After driving 893
14 Malfunctions during crane operation 897
14 1 Emergency stop switches 897
14 2 What to do when malfunctions occur during crane operation 899
The load can be set down 899
Load cannot be set down 899
14 3 Fuses in the crane cab 901
Information on replacing fuses 901
14 4 Troubleshooting 906
14 4 1 Malfunctions on the engine 906
14 4 2 Malfunctions when operating with the hand-held control 906
14 4 3 Malfunctions on the turntable lock 907
14 4 4 Malfunctions when inclining the crane cab 907
14 4 5 Malfunctions on the main hoist 908
14 4 6 Malfunctions in the telescoping mechanism 909
14 4 7 Malfunctions in the hoist cameras 910
14 4 8 Malfunctions in the main boom camera 910
14 4 9 Malfunctions on the derricking gear 911
14 4 10 Malfunctions on the slewing gear 912
14 4 11 Malfunctions on the counterweight hoist unit 913
14 4 12 Malfunctions in the hydraulic system/hydraulic oil cooler 914
14 4 13 Malfunctions when driving from the crane cab 914
14 4 14 Malfunctions of the outriggers 915
14 4 15 Troubleshooting the crane control 917
General malfunctions 918
Symbols in the error or information display areas 918
Displays in the Error menu 922
14 4 16 Malfunctions on the CraneSTAR system 924
14 5 Emergency operations and programs 925
14 5 1 Mechanical emergency activation for retracting 926
Prior to the emergency activation, check 926
Procedure 926
Mechanical emergency activation 927
14 5 2 Telescoping emergency program 929
Open the Emergency program submenu 929
Determining the type of error 930
If there is an error on the length indicator 931
Tables for approaching the locking points 935
14 5 3 Entering the current telescoping 937
14 5 4 Emergency operation with the hand-held control 939
Preparations 939
Pre-selecting a power unit 940
Operating apowerunit 940
Stopping movements 941
Stopping movements in emergencies 942
Switching off theengine 942
14 6 Hydraulic emergency operation 943
Switching over valves 943
Releasing/ securing valves 944
For lowering 945
14 6 1 Performing emergency activation 947
14 6 2 After the emergency activation 947
14 6 3 Operating principle of emergency operation BGR 159 948
14 6 4 Connecting/disconnecting hoses 949
Establishing connections 949
Disconnecting connections 950
14 6 5 Switching emergency operation on/off 951
14 6 6 Establishing the hydraulic circuits required 951
Switching over valves 951
For lifting/ lowering 953
For slewing 954
14 6 7 Performing emergency operation 955
Slewing 955
Derricking 956
Lifting/lowering 956
14 6 8 After emergency operation 957
Switching off emergency operation 957
Switching over to crane operation 957
Disconnecting thehoses 957
14 6 9 Emergency supply of another crane 958
For emergency supply 958
After emergency supply 958
15 Index 961
A 963
B 963
C 964
D 967
E 969
F 970
H 970
I 971
L 972
M 972
O 973
P 974
R 975
S 976
T 977
V 979
W 979

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S.M