Operation Manual for Manitowoc Grove GMK5150L Crane (PDF)

Description

Manitowoc GROVE Crane GMK5150L Operating Instructions Manual 3302557 – PDF DOWNLOAD

FILE DETAILS:

Manitowoc GROVE Crane GMK5150L Operating Instructions Manual 3302557 – PDF DOWNLOAD

Language : English
Pages :1000
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc GROVE Crane GMK5150L Operating Instructions Manual 3302557 – PDF DOWNLOAD

Additional pages 25
Installing/removing the outrigger beams 3
CCS – Datalogger 25
Additional menu and program 25
Driving with a rigged crane 23
Permissible axle loads 23
Secure the superstructure against slewing 23
Dimensions and weights of removable parts 39
Main boom 39
Telescoping emergency programme 41
Return run of the telescoping cylinder 41
1 Overview 47
1 1 Accidents 47
1 2 Branch offices 49
1 2 1 Manitowoc Crane Care 49
1 2 2 Dealer list 49
1 3 Warranty specifications 49
1 4 Terms used 50
1 5 Technical data 53
1 5 1 Maximum lifting capacity (DIN/ISO/EN) 53
1 5 2 Maximum lifting capacity (ASME B 30 5) 53
1 5 3 Dimensions and weights of the truck crane, axle loads 54
Dimensions 55
Weight and axleloads 55
1 5 4 Dimensions and weights of removable parts 56
Spare wheel 56
Outrigger 56
Hook blocks and hook tackle 56
Counterweight parts 57
1 5 5 Carrier 58
Engine 58
Transmission 58
Transfer case 58
Axle lines 58
Steering 58
Tyres 59
Outrigger 60
Electrical system 61
Tool 61
Towing coupling 61
Driving speeds 61
Climbing ability 61
Turning radii 62
1 5 6 Superstructure 62
Main hoist 62
Auxiliary hoist 63
Slewing gear 63
Derricking gear 63
Main boom 63
Lattice extension 63
Operating speeds 64
1 6 Documentation supplied 65
1 6 1 Questions on documentation 66
1 7 Notes on the operating manual 67
1 7 1 What do the symbols used mean? 67
1 7 2 How is the operating manual structured? 69
Division 69
Structure of thechapters 69
Structure of thepages 70
1 7 3 How do I find the information I need? 71
Cross-references example 72
1 7 4 What information is available for operations planning? 74
1 8 Conversion table for US measuring units 75
1 9 Training – Information 77
1 10 Identification 78
1 11 EC Declaration of Conformity 80
2 Basic safety instructions 83
2 1 Intended use 83
2 1 1 Improper use 84
2 2 Organisational measures 85
2 3 Personnel qualifications 87
2 4 Safety instructions for driving the truck crane 89
2 5 Safety instructions for crane operation 91
2 6 Instructions on transporting persons 95
Equipment for lifting persons 95
Personnel 96
Operation 96
Truck crane 97
3 Operating elements for driving 101
3 1 Overview of the operating elements 101
3 1 1 Exterior of the truck crane 102
3 1 2 Driver’s cab 106
Front overview 106
Rear overview 108
Behind the cover 109
3 1 3 Steering column/steering wheel 111
3 1 4 Instrument panel 113
Left/right 113
Middle 114
3 1 5 Transmission operating elements 116
3 1 6 On-board computer 117
3 1 7 Tachograph, on-board computer time correction 118
3 1 8 Heating and air-conditioning system 119
Standard 119
Auxiliary water heating system 120
Auxiliary air heater 121
3 1 9 CCS control unit 122
3 1 10 CCS display – Start menu 123
3 1 11 CCS – Overview menu groups 124
Carrier menu group 126
Suspension/level adjustment menu 127
Driving menu 128
Settings menu group 129
Menu for setting the display brightness anddate/time 130
Switch units menu 131
Information menu group 132
Operating hours menu 133
Engine/transmission error menu 134
Crane operation error menu 135
Operating additional equipment 136
Emergency operation 137
3 1 12 Outriggers control units 138
3 2 Brief description of the operating elements 139
3 2 1 Definition of direction references 139
Basic rule 139
Switches and buttons 140
3 2 2 General rules for buttons and symbols on the display 140
3 2 3 Crane control CCS 141
3 2 4 Engine 146
Steering column 146
On the steering wheel 146
Instrument panel 147
3 2 5 AdBlue system 148
Instrument panel 148
CCS display 149
3 2 6 Battery master switch 149
3 2 7 Electrical system 150
3 2 8 Transmission 151
Transmission control unit 151
Display driving mode 153
3 2 9 Reverse camera 154
3 2 10 BirdView system 270 155
3 2 11 Transfer case 157
3 2 12 Final drive 158
3 2 13 Brakes 160
Service brake 160
Parking brake 160
Additional brakes 161
3 2 14 Steering / separate steering 162
Instrument panel 162
CCS display 164
3 2 15 Suspension 166
CCS display 166
Outriggers control units 166
3 2 16 Lighting/windscreen wipers/horn 167
Steering column 167
Steering wheel 167
Instrument panel 167
CCS display 169
Roof 169
3 2 17 Level adjustment system 170
3 2 18 Tachograph/speedometer 172
Tachograph 172
Speedometer 172
3 2 19 Diagnostics 173
3 2 20 On-board computer 174
3 2 21 Push-up roof 175
3 2 22 Windows and doors 176
Window winder 176
Doors 177
3 2 23 Front flap 178
4 Starting/switching off the engine – for driving 181
4 1 Starting the engine from the driver’s cab 181
4 1 1 CHECKLIST: Starting the engine 181
4 1 2 CHECKLIST: At low temperatures 184
4 1 3 Ladders 185
Folding ladder 186
4 1 4 Refuelling 187
Fuel tank 187
AdBlue tank 189
4 1 5 Checks before starting the engine 190
At the hydraulic tank 190
Battery master switch 191
Checking the hand-held control 191
4 1 6 Switching on the ignition 191
4 1 7 Lamp test/equalisation of the switching states 192
Lamp test 192
Alignment of theswitching statuses 192
4 1 8 Display brightness 193
4 1 9 Start the engine 194
4 1 10 Inspections after starting the engine 196
Main menu and on-board computer display 196
Instrument panel 197
4 1 11 Adjust idling speed 199
4 2 Switching off the engine 201
4 2 1 At the ignition lock and with the outrigger control units 201
After turning off 201
4 2 2 With emergency stop switches 202
Resetting the emergency stop switch 202
4 3 Air intake inhibitor 203
Releasing the air intake inhibitor 203
5 Driving mode 207
5 1 Before driving 207
5 1 1 CHECKLIST: Checks before on-road driving 207
5 1 2 Checking the condition of the truck crane 213
Electrical system 213
Adjust the mirrors 213
Warning plates for vehicle width 214
Displaying vehicle height 215
Supply pressure 216
Parking brake 217
5 1 3 Adjusting the seats and steering column 219
Adjusting the driver’s seat 219
Adjusting the passenger’s seat 220
Steering column, adjusting 221
5 1 4 Switching the suspension on/off 222
Open menu 222
Switching the suspension on 223
Switching off the suspension 223
5 1 5 Setting the tachograph 224
Prerequisites 224
In the event of malfunctions 224
Setting the tachograph 225
5 1 6 Entering the time/date 229
5 1 7 Displaying and resetting operating hours 230
5 2 Operating the transmission 231
5 2 1 Switching on 231
5 2 2 Switching the transmission to the neutral position 232
5 2 3 Selecting the direction of travel and starting gear 233
Selecting the driving direction 233
Selecting the starting gear  234
5 2 4 Changing the operating mode 235
Changing to automatic mode 235
Changing to manual mode 235
5 2 5 Starting 236
5 2 6 Driving and changing gears 237
In automatic operating mode 237
In manual operating mode 238
5 2 7 Changing the driving direction 239
5 2 8 Stopping 239
Stopping for a long period of time 239
5 2 9 On the roller type dynamometer 240
5 2 10 Preheating transmission 240
5 3 Driving and turning off the truck crane 241
5 3 1 Checks while driving 241
Immediately after you start to move 241
While driving 243
5 3 2 Cruise control 244
Switching on 244
Switching off 245
5 3 3 Temposet 245
Switching on 245
Switching off 246
5 3 4 Driving downhill 247
Starting 247
Inspections when driving downhill 248
Downshifting 248
Additional brakes 249
5 3 5 Driving uphill 251
Starting 251
Driving 251
5 3 6 Warning or malfunction messages on the instrument panel 252
Meaning of thelamps 252
5 3 7 Messages on the on-board computer display 253
5 3 8 Indicator lights in the on-board computer display 255
5 3 9 Overriding the torque reduction 257
5 3 10 Warnings in the start menu 258
5 3 11 Switching the truck crane off 259
Secure it against rolling away 260
When stationary for more than 8hours 261
5 3 12 Fold-up berth 262
5 4 Off-road driving 263
Adjustments to the transmission 263
Connections 263
Changing the vehicle level 263
Rocking the vehicle free and towing 263
5 4 1 Transfer case – switching the off-road gear on/off 264
Neutral position 264
5 4 2 Longitudinal and transverse differential locks 265
5 4 3 Operating the level adjustment system 267
Open menu 267
Setting the on-road level 268
Pre-selecting suspension struts 268
Changing the vehicle level 269
Viewing the current inclination 269
Exiting the menu 270
5 4 4 Freeing an immobilized truck crane 271
Rocking the truck crane free 271
Towing free to thefront 272
Towing free in reverse gear 272
5 5 Separate steering 273
5 5 1 Switching to separate steering 274
5 5 2 Switching to normal steering mode 277
5 5 3 Switching units of measure 278
5 6 Heating and air-conditioning system 279
5 6 1 Standard heating system 279
Switching on 279
Heating 279
Air distribution 280
Examples 281
Switching off 281
5 6 2 Air-conditioning system 282
Information 282
Switching on/off 282
Cooling 283
Drying 283
5 6 3 Auxiliary water heating system 285
Preheating theengine 285
Preheating the driver’s cab 286
Switching on 286
Adjusting thedateand time 288
Storing the heating start 289
5 6 4 Auxiliary air heater 291
Switching on 291
Setting the heating level 292
Setting the day and time 293
Setting the preselection time 293
Deleting preselection times 295
Switching off 295
5 7 Towing a trailer 297
Effects on the axleloads 297
Coupling thetrailer 298
Connecting the supply lines 299
Removing supplylines 300
Uncoupling thetrailer 300
Checking the braking force 302
6 Driving modes 305
6 1 Driving modes 305
Information on the axle loads 305
6 1 1 How to use the tables: 306
6 1 2 Table for a maximum axle load of 12 t (26,500 lbs) 307
385/95 R25 tyres 307
445/95 R25 tyres 308
525/80 R25 tyres 309
6 1 3 Maximum permitted speeds with an axle load of over 12 t (26500 lbs) 310
6 2 Weighing the truck crane 311
Axle groups 312
Weighing procedure 313
Evaluation 314
6 3 Rigging work for driving with a trailer 315
6 3 1 Switching on the slewing gear freewheel 316
6 3 2 Switching on the boom floating position 317
6 3 3 Switching on boom pre-tensioning 318
6 3 4 Raising/lowering the 3rd axle line for towing a trailer 319
Lifting 319
Lowering 319
6 4 Rigging the main boom 321
Additional equipment required 321
6 4 1 CHECKLIST: removing the main boom 322
Prerequisites 322
Checklist 322
6 4 2 CHECKLIST: installing the main boom 325
Prerequisites 325
Checklist 325
6 4 3 Slinging the main boom 328
Marking 328
Installing the lifting gear 328
Removing the lifting gear 329
6 4 4 Switching the pressure relief on/off 330
6 4 5 Retracting/fitting the derricking cylinder head pin 331
Retracting the derricking cylinder head axle 332
Fitting the derricking cylinder head axle 333
6 4 6 Extending/retracting the boom pivot pin 334
Before pulling itout 334
After pushing it in 334
Pulling out the pivot pin 335
Pushing the pivotpin in 336
6 4 7 Removing/attaching the clamps 338
6 4 8 Disconnecting/connecting hydraulics/electrical 339
Disconnecting 339
Connecting 340
6 4 9 Aligning the connecting points 341
6 4 10 Securing/releasing the derricking cylinder 342
6 4 11 Transporting the main boom 342
6 4 12 Inspections after main boom mounting 343
6 5 Installing/removing the auxiliary hoist 345
6 5 1 Slinging the auxiliary hoist 345
6 5 2 CHECKLIST: Installing the auxiliary hoist 346
6 5 3 CHECKLIST: Removing the auxiliary hoist 347
6 5 4 Making/breaking the connection between the auxiliary hoist and the turntable 348
6 5 5 Establishing/disconnecting the hydraulic connection 349
6 5 6 Establishing/disconnecting the electrical connection 350
6 5 7 Making/breaking the connection to the central lubrication 351
6 5 8 Transporting the auxiliary hoist 352
6 5 9 Check that the auxiliary hoist is functioning properly 353
Slewing direction 353
Slewing indicator 353
7 Transport 357
7 1 Transport with transport vehicle 357
7 1 1 CHECKLIST: Checks before transport 358
7 1 2 Drive the truck crane on to the transport vehicle 360
Driving on 361
Lashing 361
7 2 Transport by ship 362
8 Malfunctions in driving mode 363
8 1 Emergency stop switches 363
8 2 What to do when a malfunction occurs in road traffic 365
8 3 Towing away the truck crane 367
8 3 1 Towing after engine/transmission damage 368
Compressed-air supply 368
Electric power supply 368
On the transmission 369
Axle drives 369
Parking brake 370
Towing the truck crane out of the danger area 371
Longer towing distances 371
8 3 2 Tow starting 371
8 4 Other emergency operations 373
8 4 1 Externally starting the truck crane 373
8 4 2 Battery charger 374
Prerequisites 374
8 5 Wheels and tyres 375
8 5 1 Wheel change 375
Removing a damaged wheel 376
On the spare wheel holder 376
Mounting a wheel 377
8 5 2 Inflating the tyres yourself 379
Connecting the filling hose 379
Inflating the tyres 380
Remove the fillinghose 380
8 6 Tilting/lowering the driver’s cab 381
8 6 1 Prerequisites and information on tilting 381
8 6 2 Tilting/lowering the driver’s cab 382
Operating the hand pump 382
Tilting the driver’scab 383
Lowering the driver’s cab 384
8 7 Fuses on the carrier 387
Information on replacing fuses 387
8 7 1 Fuses in the driver’s cab 388
8 7 2 Fuses in the battery box 394
8 8 Troubleshooting 395
8 8 1 Malfunctions on the engine 395
When operating with the dual tank 397
8 8 2 Faults on the Adblue system 397
8 8 3 Malfunctions of the differential locks 398
8 8 4 Malfunctions in the transmission 399
8 8 5 Malfunctions of the steering 400
8 8 6 Malfunctions of the service brake 401
8 8 7 Malfunctions on the suspension 402
8 8 8 Malfunctions of the level adjustment system 402
8 8 9 Malfunctions in the hydraulic system/hydraulic oil cooler 402
8 9 CCS warning/error message 403
Symbols in the display area 403
8 9 1 Engine/transmission error menu 407
Open menu 407
Exiting the menu 407
8 10 Procedure during malfunctions 409
8 10 1 Procedure during engine malfunctions 409
8 10 2 Procedure during transmission malfunctions 410
9 Operating elements for crane operation 415
9 1 Overview of the operating elements 415
9 1 1 Exterior of the truck crane 416
9 1 2 Crane cab 420
Side panel 422
Crane cab, rear 424
9 1 3 Control panels 426
Left 426
Right 427
9 1 4 Control lever configuration 428
Version 1 428
Version 2 429
9 1 5 CCS control unit 430
9 1 6 CCS – Start menu 433
9 1 7 CCS – Overview menu groups 434
Superstructure menu group 438
Superstructure lock sub-menu 439
Counterweight menu 440
Outrigger menu 441
Outrigger support beam menu 443
Outrigger cylinders menu 444
Menu group Teleautomation 446
Telescoping full automation menu 447
Telescoping semi- automation menu 448
Manual telescoping menu 449
Main boom configuration menu 450
Active working range limiter menu group 451
Overall height menu 452
Working radius menu 453
Slewing angle menu 454
Hoist rope travel limitation menu 455
Information menugroup 456
Hydraulic pressure and fuel consumption menu 457
Engine/Driving menu group 459
Driving mode menu 460
Economy mode menu 462
Remote control menu 463
Heating/air-conditioning menu 464
Spotlights menu 465
Telescoping emergency program menu group 466
Unknown telescoping menu 467
Telescoping emergency program menu 468
Settings menu group 469
Crane cab menu 470
Menu for setting the display brightness and date/ time 471
Switch units menu 472
Set control lever characteristic curve menu 473
Power unit speeds menu 474
Information menu group 475
Operating hours menu 476
Engine/transmission error menu 477
Crane operation error menu 478
Program version menu 479
Operating additional equipment 480
9 1 8 RCL control unit 481
9 1 9 RCL – menu groups 484
Enter rigging mode menu 486
Monitoring menu 487
Lifting capacity table menu 488
9 1 10 Hand-held control 489
9 1 11 Outriggers control units 490
Button 490
Outrigger button 491
Inclination and outrigger pressure display 492
Raise axle display 493
9 2 Brief description of the operating elements 495
9 2 1 Definition of direction references 495
Basic rule 495
Switches 495
9 2 2 General rules for buttons and symbols on the display 496
9 2 3 Crane control CCS 497
9 2 4 Engine 504
Side panel 504
CCS display 504
Economy mode menu 505
Left control lever 505
9 2 5 AdBlue system 506
CCS display 506
9 2 6 Seat contact switch and dead man’s switch 507
9 2 7 Outrigger 509
Right-hand control panel 509
Left-hand controlpanel 509
In the Outrigger menu 510
At the outrigger control units 513
9 2 8 Inclination indicators 515
9 2 9 Raise axle 516
Outriggers control units 516
CCS display 517
9 2 10 Outrigger pressure displays 518
Outrigger submenu 518
Outriggers controlunits 518
9 2 11 Anemometer displays 518
9 2 12 Counterweight menu 520
Counterweight submenu 520
9 2 13 Main hoist 524
Control panels 524
CCS display 524
9 2 14 Auxiliary hoist 526
Control panels 526
CCS display 526
9 2 15 Slewing gear 528
Control panels 528
CCS display 529
9 2 16 Derricking gear 530
Control panels 530
CCS display 531
9 2 17 Telescoping mechanism 532
Control panels 532
CCS display 532
Telescoping full automation menu 533
Telescoping semi- automation menu 534
Manual telescoping menu 536
Main boom configuration menu 539
9 2 18 Hydraulic system 540
9 2 19 Superstructure lock/house lock menu 541
Superstructure lock 541
Houselock 542
9 2 20 Remote control 543
9 2 21 Rated capacity limiter (RCL) 544
Control unit control console RCL 544
Display RCL 545
Enter rigging mode menu 546
Monitoring menu 550
Lifting capacity tables menu 554
RCL override – version A 555
RCL override – Version B 556
9 2 22 Electrical system 557
9 2 23 Lighting, windscreen wiper/washing system 558
Lighting 558
Windscreen wiper/washing system 560
9 2 24 Hand-held control 562
Sockets for hand-held control 562
Engine control panel 563
Horn 563
Outriggers control panel 564
9 2 25 Windows and doors 566
Windows 566
Rear window 566
Crane cab door 567
9 2 26 Diagnostics 568
9 3 Short description of the operating elements – driving from the crane cab 569
9 3 1 Driving mode menu 569
9 3 2 Transmission 570
9 3 3 Final drive 571
9 3 4 Brakes 572
CCS display 572
Side panel from above 573
9 3 5 Steering 574
CCS display 574
Separate steering 575
Control panels 577
10 Starting/switching off the engine – for crane operation 581
10 1 When starting the engine for the first time in the day 581
10 2 Starting the engine – from the crane cab 583
10 2 1 Check the fuel level and AdBlue level 583
Fuel 583
AdBlue 583
10 2 2 Checks before starting the engine 584
Checks on thecarrier 584
Checking the hand-held control 584
At the hydraulic tank 584
10 2 3 Switching on the ignition 585
10 2 4 Alignment of the switching statuses 586
Alignment of theswitching statuses 586
10 2 5 Display – setting the brightness 587
10 2 6 Start the engine 588
10 2 7 Inspections after starting the engine 589
10 2 8 Adjust idling speed 590
10 3 Starting the engine – with the hand-held control 591
10 4 Switching off the engine 593
10 4 1 At the ignition lock and with hand-held control 593
After turning off 593
10 4 2 With the idling button 593
10 4 3 Using the emergency stop switches 594
Resetting the emergency stop switch 594
11 Crane operation 597
11 1 Before operating the crane 597
11 1 1 CHECKLIST: Checks before operating the crane 597
11 1 2 Checking the condition of the truck crane 601
Fuel tank auxiliary heater 601
Visual inspection 601
Checking the position of the hoist ropes 602
Checking the electrical system 603
11 1 3 Adjusting the crane cab seat and front control panel 604
Crane cab seat 604
Front panel 605
11 1 4 Checking the safety equipment 606
Rated capacity limiter 606
Lifting limit switch 606
Emergency stop switches 607
Seat contact switch 608
11 1 5 Earthing the load 609
11 1 6 Preheating the hydraulic oil 610
Prerequisites 610
Preheating 610
11 1 7 Locking/unlocking the superstructure 611
Locking points 611
Locking the superstructure 612
Unlocking the superstructure 612
11 1 8 Switching the houselock on/off 613
Switching on the houselock 613
Switching off the houselock 615
11 2 Operation of the rated capacity limiter 617
11 2 1 Switch on the RCL 618
Switching on 618
Brightness of thedisplays 620
Temperature on the display 620
11 2 2 Enter rigging mode 621
Entering individual components 622
Entering the RCLcode 627
Enter the reeving 628
Accepting the rigging mode 628
11 2 3 Checks before operating the crane 630
Open menu 630
Checks 630
11 2 4 Displays during crane operation 633
11 2 5 RCL early warning 636
11 2 6 RCL shutdown 636
Shutdown due tooverload 636
11 2 7 Display in the event of errors 638
11 2 8 RCL override – version A 639
Overview status display 639
When rigging 640
To raise the boom 641
In emergencies 642
11 2 9 RCL override – version B 643
11 2 10 Displaying the lifting capacity tables 644
11 2 11 Setting the time/date 646
11 3 Crane operation with main boom 647
11 3 1 Checks during crane operation 647
Horizontal alignment 647
Safe distances 647
Checking the windspeed 648
11 3 2 Permissible slewing ranges and working positions 649
360 slewing range 649
Working position 0 to the rear 649
180 to the front rigging position 649
11 3 3 Main hoist 651
Switching on the main hoist 652
Lifting and lowering 652
Maximum permissible hoist rope speed 652
Switching off the main hoist 653
11 3 4 Auxiliary hoist 655
Switching on the auxiliary hoist 655
Lifting and lowering 656
Maximum permissible hoist rope speed 656
Switching off the auxiliary hoist 657
11 3 5 Lifting limit switch and lowering limit switch 659
Lifting limit switch 659
Lowering limit switch 661
11 3 6 Derricking gear 662
Switching on the derricking gear 662
Maximum permissible derricking speed 662
Raising and lowering 663
Re-enable raising function 664
Switching off the derricking gear 664
11 3 7 Telescoping mechanism 666
Overview 667
Telescoping process 668
Assignment fordisplay 670
Fixed length, intermediate length, telescoping length 671
Telescoping 672
Telescoping sequence 672
Checks before starting work 673
Switching on thetelescoping mechanism 674
Function of the control lever 674
Switching off thetelescoping mechanism 676
Manual telescoping 677
Checking the initial position 677
Unlocking the telescoping cylinder 679
Extending/ retracting the telescoping cylinder 681
Locking the telescoping cylinder 682
Unlocking the telescopic section 683
Telescoping the telescopic section 684
Locking the telescopic section 685
Locking the telescopic section for on-road driving 686
Telescoping with semi-automaton 686
Telescoping with full automation 689
Telescoping withmain boom configuration 690
11 3 8 High-speed mode 691
Derricking gear telescoping mechanism 691
Hoists 691
11 3 9 Slewing gear 693
Switching on the slewing gear 693
Releasing the slewing gear brake 693
Applying the slewing gear brake 694
Slewing 694
Releasing locked slewing gear 694
Maximum permitted slewing speed 695
Braking the slewing movement 696
Slewing gear freewheel 696
Switching off the slewing gear 697
11 3 10 Possible movement combinations 698
11 4 Settings and displays for crane operation 699
11 4 1 Inclining the crane cab 699
11 4 2 Adjust idling speed 700
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 700
11 4 4 Limiting the power unit speeds 701
11 4 5 Economy mode 702
Switching on 702
Switch off/exit 704
11 4 6 Switching units of measure 705
11 4 7 Setting the characteristic curves for the control levers 706
11 4 8 Using the slewable spotlights 707
Manually swinging 707
Automatic load tracking 708
11 4 9 Overriding the torque reduction 709
11 4 10 Displaying the operating hours 710
11 4 11 Warnings in the start menu 712
Meaning of the symbols 712
11 5 Working range limiter 716
11 5 1 Viewing current settings 717
11 5 2 Opening the working range limiter menu 717
11 5 3 Entering limit values 720
Overall height 720
Working radius 721
Slewing angle 721
Hoist rope travel limitation 722
11 5 4 Entering limit values manually 723
Limit values 723
11 5 5 Switching monitoring functions on/off 725
11 5 6 Shutdown by working range limiter 726
11 6 Work break 727
11 6 1 In case of short work breaks 727
11 6 2 In case of work breaks of more than 8 hours 728
To secure the truck crane 728
11 7 Heating and air-conditioning system 729
11 7 1 Standard heating system 729
Switching on 729
Heating 729
Air distribution 730
Switching off 730
11 7 2 Air-conditioning system 731
Information 731
Switching on/off 731
Cooling, automatic 732
Cooling, maximum 732
11 7 3 Auxiliary heater 733
Switching on 733
Adjusting the temperature 734
Setting the heating start/ heating duration 734
Switching heating start on/off 735
11 8 CraneSTAR system 736
11 8 1 Overview 736
11 8 2 Position of the components 736
12 Rigging work 739
12 1 Rigging work checklists for crane operation with the main boom 739
12 1 1 CHECKLIST: Rigging 739
12 1 2 CHECKLIST: Unrigging 745
12 2 Selecting the suitable site 749
12 2 1 Determining the required load-bearing area 749
12 2 2 Safe distance from slopes and pits 752
12 2 3 Earthing the truck crane 753
12 2 4 Safe distance from overhead power lines 754
12 3 Rigging work after driving with a trailer 757
12 3 1 Switching off the boom floating position 757
12 3 2 Switching off the slewing gear freewheel 758
Before slewing 758
12 3 3 Switching off boom pre-tensioning 759
12 4 Connecting/disconnecting the hand-held control 761
12 5 Starting the engine for rigging 763
12 5 1 Starting/turning off the engine with the hand-held control 763
Prerequisites 763
Start the engine 764
Switching off theengine 764
12 5 2 Starting/switching off the engine from the outrigger control units 765
Prerequisites 765
Start the engine 765
Switching off theengine 765
12 6 Outrigger 767
12 6 1 CHECKLIST: Extending the outriggers 767
12 6 2 CHECKLIST: Retracting the outriggers 769
12 6 3 Permissible outrigger spans 770
12 6 4 Preparing the truck crane 771
Driver’s cab 771
Crane cab 771
12 6 5 Setting the spans 773
For on-road driving 775
12 6 6 Extending/retracting outrigger beams 777
From the control units 778
From the cranecab 779
12 6 7 Moving the outrigger pads into operating/driving position 781
12 6 8 Enlarging the load-bearing area 783
12 6 9 Extending/retracting supporting cylinders 784
From the controlunits 785
From the cranecab 786
12 6 10 Levelling the truck crane on outriggers 788
Inclination indicators 788
Prerequisites 789
Manual alignment 790
Automatic alignment 791
12 6 11 Levelling the free-on-wheels truck crane 792
12 6 12 Outrigger pressure display 794
12 7 Rigging/unrigging the counterweight 795
12 7 1 Information on rigging 795
When rigging 796
When unrigging 797
12 7 2 Counterweight sections 798
Version 1 798
Version 2 798
Version 3 799
12 7 3 Identification 800
12 7 4 Slinging points on the counterweight sections 801
12 7 5 CHECKLIST: Rigging the counterweight 803
12 7 6 CHECKLIST: Unrigging the counterweight 805
12 7 7 Assembling counterweight versions 807
Setting down the 2 3 t base plate 808
Setting down the top counterweight section 808
Version 1 809
Version 2 817
Version 3 821
12 7 8 Counterweight hoist unit 829
Counterweight menu 829
Extending/ retracting the lifting cylinders 830
Automatic moderigging 832
Automatic mode unrigging 834
Cancel automatic mode 835
12 7 9 Removing/installing the counterweight on the turntable 836
Removing 836
Installing 837
12 7 10 Setting down counterweight for driving the truck crane 838
Version 1 and 3 838
Version 2 840
12 7 11 Slewing with the rigged counterweight 841
12 8 Rigging work on the main boom 843
12 8 1 Hook block on the bumper 843
Picking up the hook block 843
Attaching the hook block 844
12 8 2 Hook block on a separate vehicle 845
Picking up the hook block 846
Setting down the hook block 846
12 8 3 Hook block, separable 848
Rigging for on-road driving 848
Rigging for crane operation 849
12 8 4 Reeving and unreeving the hoist rope 850
Version A 850
Version B 851
Reeving the hoist rope 853
Unreeving hoist rope 857
12 8 5 Possible reeving methods on the main boom 858
With 6 head sheaves 858
With 8 head sheaves 860
With 9 head sheaves 864
12 8 6 Installing/removing the lifting limit switch 865
Installing lifting limit switch 865
Removing the lifting limit switch 868
12 8 7 Locking/unlocking the lifting limit switch 870
Locking 870
Unlocking 870
12 8 8 Anemometer and air traffic control light 871
Installing 871
Switching the air traffic control light on and off 872
Removing 872
12 9 Other rigging works 875
12 9 1 Folding the mirrors in and out, and adjusting them 875
12 9 2 Cameras for crane operation 876
Camera on mainboom 876
Camera on thehoists 878
Camera on the driver’s cab 878
Operating the camera 879
12 9 3 Railings on the turntable 880
12 9 4 Step for the crane cab 881
12 9 5 Slinging points for personal protective equipment 882
13 Driving with a rigged truck crane 885
13 1 Driving path 885
13 2 Permissible rigging modes and axle loads 886
Axle load table 887
13 2 1 To drive without a load 888
13 2 2 To drive with a load 889
13 2 3 Axle loads 889
13 3 Before driving the rigged truck crane 890
13 3 1 Check the tyre pressures and wind speed 890
13 3 2 Securing the superstructure against slewing 890
13 3 3 Putting the truck crane on the wheels 891
13 4 Driving from the driver’s cab 893
13 4 1 Preparing to drive 893
Transmission 893
Switching on separate steering 893
Connections 893
13 4 2 While driving 894
13 4 3 After driving 895
13 5 Driving from the crane cab 897
13 5 1 Preparing to drive 898
13 5 2 Opening/closing the Driving menu 898
Opening 898
Crane hydraulic system on/off 899
Closing 900
13 5 3 Steering 901
Switching on 901
Steering direction 901
Displays when steering 902
Separate steering 902
Normal steering mode 906
13 5 4 Operating the transmission 907
Selecting the transmission mode 907
13 5 5 While driving 908
DMand RM transmission mode 908
Transmission mode D 908
Warning messages 908
13 5 6 Possible connections 909
Longitudinal/ transverse differential locks 909
13 5 7 After driving 911
14 Malfunctions during crane operation 915
14 1 Emergency stop switches 915
14 2 What to do when malfunctions occur during crane operation 917
The load can be set down 917
Load cannot be set down 917
14 3 Fuses in the crane cab 919
Information on replacing fuses 919
14 4 Troubleshooting 924
14 4 1 Malfunctions on the engine 924
14 4 2 Malfunctions when operating with the hand-held control 924
14 4 3 Malfunctions on the turntable lock 925
14 4 4 Malfunctions when inclining the crane cab 925
14 4 5 Malfunctions on the main hoist 926
14 4 6 Malfunctions in the telescoping mechanism 927
14 4 7 Malfunctions in the hoist cameras 928
14 4 8 Malfunctions in the main boom camera 928
14 4 9 Malfunctions on the derricking gear 929
14 4 10 Malfunctions on the slewing gear 930
14 4 11 Malfunctions on the counterweight hoist unit 931
14 4 12 Malfunctions in the hydraulic system/hydraulic oil cooler 932
14 4 13 Malfunctions when driving from the crane cab 932
14 4 14 Malfunctions of the outriggers 933
14 4 15 Troubleshooting the crane control 935
General malfunctions 936
Symbols in the error or information display areas 936
Displays in the Error menu 940
14 4 16 Malfunctions on the CraneSTAR system 942
14 5 Emergency operations and programs 943
14 5 1 Mechanical emergency activation for retracting 944
Prior to the emergency activation, check 944
Procedure 944
Mechanical emergency activation 945
14 5 2 Telescoping emergency program 947
Open the Emergency program submenu 947
Determining the type of error 948
If there is an error on the length indicator 949
Tables for approaching the locking points 953
14 5 3 Entering the current telescoping 955
14 5 4 Emergency operation with the hand-held control 957
Preparations 957
Pre-selecting a power unit 958
Operating apowerunit 958
Stopping movements 959
Stopping movements in emergencies 960
Switching off theengine 960
14 6 Hydraulic emergency operation 961
Switching over valves 961
Releasing/ securing valves 962
For lowering 963
14 6 1 Performing emergency activation 965
14 6 2 After the emergency activation 965
14 6 3 Operating principle of emergency operation BGR 159 966
14 6 4 Connecting/disconnecting hoses 967
Establishing connections 967
Disconnecting connections 968
14 6 5 Switching emergency operation on/off 969
14 6 6 Establishing the hydraulic circuits required 969
Switching over valves 969
For lifting/ lowering 971
For slewing 972
14 6 7 Performing emergency operation 973
Slewing 973
Derricking 974
Lifting/lowering 974
14 6 8 After emergency operation 975
Switching off emergency operation 975
Switching over to crane operation 975
Disconnecting thehoses 975
14 6 9 Emergency supply of another crane 976
For emergency supply 976
After emergency supply 976
15 Index 979
A 981
B 981
C 982
D 985
E 987
F 988
H 988
I 989
L 990
M 990
O 991
P 992
R 993
S 994
T 995
V 997
W 997

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S.M