Manitowoc Grove Crane GMK5150L Operating Manual 3302708 PDF

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Manitowoc Grove Crane GMK5150L Operating Manual 3302708 – PDF DOWNLOAD

The Manitowoc Grove Crane GMK5150L Operating Manual (3302708) is a crucial PDF guide. Download for comprehensive insights into GMK5150L operation, providing essential instructions for safe and efficient crane usage.

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Manitowoc Grove Crane GMK5150L Operating Manual 3302708 – PDF DOWNLOAD

Language : English
Pages :1040
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Grove Crane GMK5150L Operating Manual 3302708 – PDF DOWNLOAD

Operating manual 0
Additional pages 5
Outrigger spans 3
Driving from the crane cab 5
Telescoping emergency programe 7
Hook blocks – Change / Correction 9
Crane cab heating and air-conditioning system 13
Operation from the driver’s cab 13
Table of contens 17
General 47
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 Dimensions and weights of the truck crane, axle loads 54
Dimensions 55
Weight and axleloads 55
1 5 3 Dimensions and weights of removable parts 56
Spare wheel 56
Outrigger 56
Main boom 56
Hook blocks andhook tackle 57
Auxiliary hoist 59
Counterweight parts 60
1 5 4 Carrier 63
Engine 63
Transmission 63
Transfer case 63
Axle lines 63
Steering 64
Tyres 64
Turning turningradii 64
Outrigger 65
Electrical system 66
Tool 66
Towing couplings 66
Driving speeds 66
Climbing ability 66
1 5 5 Superstructure 67
Main hoist 67
Auxiliary hoist 67
Slewing gears 67
Derricking gear 67
Main boom 68
Lattice extension 68
Operating speeds 68
1 6 Documentation supplied 69
1 6 1 Questions on documentation 70
1 7 Notes on the operating manual 71
1 7 1 What do the symbols used mean? 71
1 7 2 How is the operating manual structured? 73
Division 73
Structure of the chapters 73
Structure of thepages 74
1 7 3 How do I find the information I need? 75
Cross-references example 76
1 7 4 What information is available for operations planning? 78
1 8 Conversion table for US measuring units 79
1 9 Training – Information 81
1 10 Identification 82
1 11 EC Declaration of Conformity 84
2 Basic safety instructions 85
2 1 Intended use 85
2 1 1 Improper use 86
2 2 Organisational measures 87
2 3 Personnel qualifications 89
2 4 Safety instructions for driving the truck crane 90
2 5 Safety instructions for crane operation 91
2 6 Instructions on transporting persons 94
Equipment for lifting persons 94
Personnel 94
Operation 95
Truck crane 96
Driving 97
3 Operating elements for driving 97
3 1 Overview of the operating elements 97
3 1 1 On the outside of the truck crane 98
3 1 2 Driver’s cab 102
Front overview 102
Rear overview 104
Behind the cover 105
3 1 3 Steering column/steering wheel 106
3 1 4 Instrument panel 107
Left/right 107
Middle 108
3 1 5 Transmission operating elements 110
3 1 6 On-board computer 111
3 1 7 Tachograph 112
3 1 8 Heating and air-conditioning system 113
Standard 113
Auxiliary water heating system 114
Auxiliary air heater 115
3 1 9 CCS control unit 117
3 1 10 CCS – menu-dependent displays 118
3 1 11 CCS – Start menu 119
3 1 12 CCS – Overview menu groups 120
3 1 13 Carrier menu group 122
Suspension/level adjustment menu 123
Driving menu 124
3 1 14 Settings menu group 125
Set display brightness and date/time menu 126
Switch units menu 127
3 1 15 Menu group Information 128
Operating hoursmenu 129
Engine/transmission error menu 130
Crane operation error menu 131
3 1 16 Various controls menu group 132
3 1 17 Emergency operations menu group 133
3 1 18 Outrigger control units 134
3 2 Short description of the operating elements 135
3 2 1 Definition of information relating to directions of movement 136
Basic rule 136
3 2 2 General rules for buttons and symbols on the display 137
3 2 3 Engine 138
Steering column 138
On the steering wheel 138
Instrument panel 139
3 2 4 AdBlue system 140
Instrument panel 140
CCS display 141
3 2 5 Battery master switch 141
3 2 6 Electrical system 142
3 2 7 Crane control CCS 143
3 2 8 Transmission 145
Transmission control unit 145
Display, drivingmode 147
3 2 9 Reverse camera 148
3 2 10 BirdView system 270 149
3 2 11 Transfer case 151
3 2 12 Final drive 153
3 2 13 Brakes 154
Service brake 154
Additional brakes 154
Parking brake 155
3 2 14 Steering/separate steering 156
Instrument panel 156
CCS display 158
3 2 15 Suspension 160
CCS display 160
3 2 16 Lighting/windscreen wipers/horn 161
Steering column 161
Steering wheel 161
Instrument panel 161
CCS display 163
Roof 163
3 2 17 Level adjustment system 164
3 2 18 Tachograph/speedometer 166
Tachograph 166
Cover 166
Speedometer 166
3 2 19 Diagnostics 167
3 2 20 Push-up roof 167
3 2 21 On-board computer 168
3 2 22 Front flap 169
3 2 23 Windows and doors 170
Window winder 170
Doors 171
3 2 24 Access ladders and ladders 173
4 Starting the engine for driving / switching it off 177
4 1 Starting the engine from the driver’s cab 177
4 1 1 CHECKLIST: Starting the engine 177
4 1 2 CHECKLIST: At low temperatures 180
4 1 3 Filling up 181
Fuel tank 181
AdBlue tank 183
4 1 4 Checks before starting the engine 184
At the hydraulictank 184
Battery master switch 185
Checking the hand-held control 185
4 1 5 Switch the ignition on 185
4 1 6 Lamp test/equalisation of the switching states 186
Lamp test 186
Switching state alignment 186
4 1 7 Display – setting the brightness 187
4 1 8 Starting the engine 189
4 1 9 Checks after starting the engine 191
Start menu andon-board computer 191
Instrument panel 192
4 1 10 Setting the idling speed 193
4 2 Switch off the engine 194
4 2 1 At the ignition lock and with the outrigger control units 194
After switching off 194
4 2 2 Using the emergency stop switches 195
Resetting the emergency stopswitch 195
4 3 Air intake inhibitor 196
Opening the air intake inhibitor 196
5 Driving 197
5 1 Before driving 197
5 1 1 CHECKLIST: checks before on-road driving 197
5 1 2 Check the condition of the truck crane 203
Electrical system 203
Adjusting themirrors 203
Warning plates for vehicle width 205
Checking the vehicle height 205
Supply pressure 206
Parking brake 207
Third brake light 208
5 1 3 Adjusting the seat and the steering column 209
Adjusting the driver’s seat 209
Adjusting the passenger seat 210
Adjusting the steering column 211
5 1 4 Switching the suspension on/off 212
Open menu 212
Switching the suspension on 213
Switching the suspension off 213
5 1 5 Setting the tachograph 214
Prerequisites 214
In the event of malfunctions 214
Setting the tachograph 215
5 1 6 Setting the time 219
5 1 7 Displaying and resetting operating hours 220
5 2 Operating the transmission 221
5 2 1 Switching on 221
5 2 2 Switching the transmission to the neutral position 222
5 2 3 Selecting the direction of travel and starting gear 223
Selecting the driving direction 223
Selecting the starting gear  224
5 2 4 Changing the operating mode 225
Changing to automatic mode 225
Change to manualmode 225
5 2 5 Starting 226
5 2 6 Driving and changing gears 227
In automatic operating mode 227
In manual operating mode 228
5 2 7 Changing the driving direction 229
5 2 8 Stopping 229
Stopping for longer periods 229
5 2 9 On the roller type dynamometer 230
5 2 10 Preheating transmission 230
5 3 Driving the truck crane and switching it off 231
5 3 1 Checks whilst driving 231
Brakes 231
ABS system 231
Steering 232
Warning messages 232
Monitoring elements 233
5 3 2 Cruise control 234
Switching on 234
Switching off 235
5 3 3 Temposet 236
Switching on 236
Switching off 236
5 3 4 Driving downhill 237
Starting 237
Checks when driving downhill 238
Downshifting 238
Additional brakes 239
5 3 5 Driving uphill 240
Starting 240
Driving 240
5 3 6 Overriding torque reduction 241
5 3 7 Switching the truck crane off 242
Secure it against rolling away 242
When stationary for more than 8hours 243
5 3 8 Fold-up berth 244
5 4 Off-road driving 245
Adjustments to the transmission 245
Connections 245
Changing the vehicle level 245
Rocking the vehicle free and towing 245
5 4 1 Transfer case – switching the off-road gear on/off 246
5 4 2 Longitudinal and transverse differential locks 247
5 4 3 Operating the level adjustment system 249
Open menu 249
Setting the on-road level 250
Pre-selecting suspension struts 250
Changing the vehicle level 251
Viewing the current inclination 252
Exiting the menu 252
5 4 4 Freeing truck crane stuck in terrain 253
Rocking the truck crane free 253
Towing free forwards 254
Towing free totherear 254
5 5 Separate steering 255
5 5 1 Switching to separate steering 256
5 5 2 Switching to normal steering mode 259
5 5 3 Switching units of measure 260
5 6 Heating and air-conditioning system 261
5 6 1 Standard heating system 261
Switching on 261
Heating 261
Air distribution 262
Examples 263
Switching off 263
5 6 2 Air-conditioning system 264
Notes 264
Switching on/off 264
Cooling 265
Drying 265
5 6 3 Auxiliary water heating system 266
Preheating theengine 266
Preheating the driver’s cab 267
Switching on 267
Setting the date and time 269
Storing the heating start 270
5 6 4 Auxiliary air heater 272
Switching on 272
Setting the heating level 273
Setting the day and time 274
Setting the preselection time 274
Preselection timesDelete 276
Switching off 276
5 7 Radio 276
5 8 Towing a trailer 277
Effects on the axleloads 277
Coupling thetrailer 278
Connecting the supply lines 279
Removing supplylines 280
Uncoupling thetrailer 280
Checking the braking force 282
6 Driving modes and rigging for on-road driving 283
6 1 Driving modes 283
Information about the axle loads 283
6 1 1 How to use the tables 284
6 1 2 Table for a maximum axle load of 12 t 285
Tyres 385/95 R25 285
Tyres 445/95 R25 286
Tyres 525/80 R25 287
6 1 3 Maximum permitted speeds with an axle load of over 12 t 288
6 2 Weighing the truck crane 289
Axle groups 290
Weighing procedure 291
Evaluation 292
6 3 Rigging work for driving with a dolly 293
6 3 1 Switching on the slewing gear freewheel 294
6 3 2 Switching on the boom floating position 295
6 3 3 Switching on boom pre-tensioning 296
6 3 4 Raising/lowering the 3rd axle line for dolly operation 297
6 4 Rigging the main boom 299
Additional equipment required 299
6 4 1 CHECKLIST: Removing the main boom 300
Prerequisites 300
Checklist 300
6 4 2 CHECKLIST: Mounting the main boom 303
Prerequisites 303
Checklist 303
6 4 3 Disconnecting/connecting hydraulics/electrical 306
6 4 4 Derricking cylinder support 308
6 4 5 Slinging the main boom 308
Marking 308
Attach lifting gear 309
Removing the sling gear 310
6 4 6 Switching the pressure relief on/off 311
6 4 7 Retracting/fitting the derricking cylinder head pin 312
Operating the lifting device 312
Pulling the derricking cylinder head axle 312
Fitting the derricking cylinder head axle 313
6 4 8 Extending/retracting the boom pivot pin 314
Pulling out the pivot pin 314
Pushing the pivotpin in 316
6 4 9 Transporting the main boom 317
6 4 10 Securing/releasing the derricking cylinder 317
6 4 11 Aligning the connecting points 318
6 4 12 Inspections after main boom mounting 319
6 5 Rigging the auxiliary hoist 321
6 5 1 Slinging the auxiliary hoist 321
6 5 2 CHECKLIST: Installing the auxiliary hoist 322
6 5 3 CHECKLIST: Removing the auxiliary hoist 323
6 5 4 Making/breaking the connection between the auxiliary hoist and the turntable 324
6 5 5 Establishing/disconnecting the hydraulic connections 325
6 5 6 Disconnecting/establishing the electrical connection 326
6 5 7 Making/breaking the connection to the central lubrication 327
6 5 8 Transporting the auxiliary hoist 328
6 5 9 Check that the auxiliary hoist is functioning properly 329
Slewing direction 329
Slewing indicator 329
6 5 10 Rigging aid for the hoist rope 330
6 6 Installing/removing the outrigger beams 333
6 6 1 CHECKLIST: Removing the outrigger beams 334
6 6 2 CHECKLIST: Installing the outrigger beams 336
6 6 3 Centre of gravity data 338
6 6 4 Preparations – for removal 338
6 6 5 Preparations – on the truck crane 339
Prerequisites 339
6 6 6 Removing/attaching outrigger pads 340
Removing the outrigger pads 340
Attaching the outrigger pads 341
6 6 7 Disconnecting/establishing hydraulic connection 342
6 6 8 Disconnecting/establishing the electrical connection 343
6 6 9 Unscrewing/screwing in the spacers 344
Unscrewing 344
Screwing in 345
6 6 10 Disconnecting/establishing the connections to the supporting box 346
6 6 11 Pulling out/Inserting the outrigger beam 346
Extending the outrigger beam 346
Inserting the outrigger beam 348
6 6 12 Transporting the outrigger beams 350
6 6 13 Note on error messages with removed outrigger beams 350
7 Transport 351
7 1 Transport with transport vehicle 351
7 1 1 CHECKLIST: Checks before transport 352
7 1 2 Drive the truck crane on to the transport vehicle 354
Driving on 355
Lashing 355
7 2 Transport by ship 356
8 Malfunctions in driving mode 357
8 1 Emergency stop switch 357
8 2 Procedure during malfunctions 358
8 2 1 What to do when a malfunction occurs in road traffic 358
8 2 2 Procedure during engine malfunctions 359
8 2 3 Procedure during transmission malfunctions 360
8 3 Warning and error messages 361
8 3 1 Warning or malfunction messages on the instrument panel 361
Meaning of thelamps 361
8 3 2 Warning and malfunction messages on the on-board computer display 365
Messages 365
Symbols 366
8 3 3 Warning messages on the CCS display 369
Symbols in the display area 369
8 3 4 Error messages on the CCS display 373
Exiting the menu 374
Special error messages 374
8 4 Troubleshooting 375
8 4 1 Malfunctions on the engine 375
When operating with the dual tank 377
8 4 2 Faults on the Adblue system 377
8 4 3 Differential lock malfunctions 378
8 4 4 Transfer case malfunctions 378
8 4 5 Malfunctions in the transmission 379
8 4 6 Malfunctions of the steering 380
8 4 7 Malfunctions of the service brake 381
8 4 9 Malfunctions of the level adjustment system 382
8 4 10 Malfunctions in the hydraulic system/hydraulic oil cooler 382
8 5 Emergency operation and breakdown assistance 383
8 5 1 Starting the truck crane externally 383
8 5 2 Battery charger 384
Prerequisites 384
8 5 3 Towing the truck crane 385
In the case of engine/transmission damage 385
Longer towing distances 388
Tow starting 388
8 5 4 Wheel change 389
Removing a damaged wheel 390
On the spare wheel holder 390
Mounting a wheel 392
8 5 5 Inflating the tyres yourself 393
Connecting thefilling hose 393
Inflating the tyres 394
Remove the fillinghose 394
8 5 6 Emergency operation, steering 3rd and 4th axle lines 395
Performing emergency operation 396
After emergency operation 398
8 6 Tilting/lowering the driver’s cab 399
8 6 1 Prerequisites and information on tilting 399
8 6 2 Tilting and lowering the driver’s cab 400
Operating the hand pump 400
Tilting the driver’scab 401
Lowering the driver’s cab 402
8 7 Fuses on the carrier 405
Information on changing fuses 405
8 7 1 Fuses in the driver’s cab 406
8 7 2 Fuses in the battery box 412
Crane Operation 413
9 Operating elements for crane operation 413
9 1 Overview of the operating elements 413
9 1 1 Exterior of the truck crane 414
9 1 2 Crane cab 418
Side panel 420
Crane cab, rear 422
9 1 3 Control panels 424
Left 424
Right 425
9 1 4 Control lever assignment 426
Version 1 426
Version 2 427
9 1 5 CCS control unit 428
9 1 6 Menu-independent displays 430
9 1 7 CCS – Start menu 431
RCL display 432
Display Slewing ranges/working radii 433
9 1 8 CCS – Overview menu groups 434
9 1 9 Superstructure menu group 438
Superstructure lock sub-menu 439
Counterweight menu 440
9 1 10 Menu group outrigger/driving 441
Outrigger menu 442
Outrigger cylinders menu 444
Driving menu 446
9 1 11 RCL/Telescoping menu group 449
Menu enter rigging mode/ telescope 450
Pre-selection telescoping menu 454
Lifting capacity tables menu 456
Telescoping semi- automation menu 457
Manual telescoping menu 458
9 1 12 Working range limiter menu group 459
Overall height menu 460
Working radius menu 461
Slewing angle menu 462
Hoist rope travel limitation menu 463
9 1 13 Information1 menu group 464
Hydraulic pressure and fuel consumption menu 465
9 1 14 Heating/Engine/Additional equipment menu group 466
Economy menu 467
Remote control menu 468
Heating/air- conditioning menu 469
Spotlights menu 470
9 1 15 Telescoping emergency program menu group 471
Telescoping emergency program menu 472
Unknown telescoping menu 474
9 1 16 Menu group, settings 475
Crane cab menu 476
Set display brightness and date/time menu 477
Switch units menu 478
Set control lever characteristic curve menu 479
Power unit speeds menu 480
9 1 17 Information2 menu group 481
Operating hoursmenu 482
Engine/ transmission error menu 483
Crane operation error menu 484
Program version menu 485
9 1 18 Various controls 487
9 1 19 RCL control unit 488
9 1 20 Menu-independent displays 489
9 1 21 RCL – menus 490
Monitoring menu 490
Lifting capacity tables menu 492
Datalogger menu 493
9 1 22 Hand-held control 495
9 1 23 Outriggers control units 497
Menu- independent buttons 497
Outrigger menu 498
Raise axle menu 500
9 2 Short description of the operating elements 501
9 2 1 Definition of information relating to directions of movement 501
Basic rule 501
9 2 2 General rules for buttons and symbols on the display 502
9 2 3 Engine 503
Side panel 503
Left control lever 503
Economy mode menu 504
9 2 4 AdBlue system 504
CCS display 504
9 2 5 Seat contact switch and dead man’s switch 506
9 2 6 Crane control CCS 507
9 2 7 Outrigger – crane cab 512
Control panels 512
CCS display 513
9 2 8 Outrigger control units 515
General information 515
Outrigger menu 516
9 2 9 Raise axle 518
9 2 10 Inclination indicators 520
9 2 11 Outrigger pressure displays 521
Outrigger menu 521
Outriggers controlunits 521
9 2 12 Anemometer displays 521
9 2 13 Counterweight menu 522
9 2 14 Main hoist 526
Control panels 526
CCS display 526
9 2 15 Auxiliary hoist 528
Control panels 528
CCS display 529
9 2 16 Slewing gear 530
Control panels 530
CCS display 531
9 2 17 Derricking gear 532
Control panels 532
CCS display 533
Side panel 533
9 2 18 Telescoping mechanism 534
Control panels 534
CCS display 535
Telescoping semi- automation menu 535
Manual telescoping menu 537
9 2 19 Hydraulic system 540
9 2 20 Superstructure lock/house lock menu 541
Superstructure lock 541
Houselock 543
9 2 21 Remote control 544
9 2 22 Rated capacity limiter (RCL) 545
CCS display 545
RCL display 554
RCL override – version A 555
RCL override – version B 556
9 2 23 Electrical system 557
9 2 24 Lighting, windscreen wiper/washing system 558
Lighting 558
Windscreen wiper/washing system 560
Horn 561
9 2 25 Hand-held control 562
Sockets for hand- held control 562
Engine control panel 563
Horn 563
9 2 26 Windows and doors 566
window 566
rear window 566
Crane cab door 567
9 2 27 Diagnostics 568
9 2 28 Other 568
9 3 Short description of the operating elements – driving from the crane cab 569
9 3 1 Driving menu 569
9 3 2 Transmission 571
9 3 3 Final drive 573
9 3 4 Brakes 574
CCS display 574
Side panel fromabove 574
9 3 5 Steering 575
CCS display 576
Control panels 578
10 Starting/switching off the engine – for crane operation 579
10 1 When starting the engine for the first time in the day 579
10 2 Starting the engine – from the crane cab 581
10 2 1 Check the fuel level and AdBlue level 581
Fuel 581
AdBlue 581
10 2 2 Checks before starting the engine 582
Checks on the carrier 582
Checking the hand-held control 582
At the hydraulic tank 582
10 2 3 Switching the ignition on 583
10 2 4 Comparison of switching states 584
10 2 5 Display – setting the brightness 584
10 2 6 Starting the engine 585
10 2 7 Checks after starting the engine 586
10 2 8 Setting the idling speed 587
10 3 Starting the engine – with the hand-held control 588
10 4 Switch off the engine 589
10 4 1 At the ignition lock and with hand-held control 589
After switching off 589
10 4 2 With the idling button 589
10 4 3 Using the emergency stop switches 590
Emergency stop switch, resetting 590
11 Crane operation 591
11 1 Before operating the crane 591
11 1 1 CHECKLIST: Checks before operating the crane 591
11 1 2 Check the condition of the truck crane 595
Fuel tank auxiliary heater 595
Visual inspection 595
Checking the position of the hoist ropes 596
Checking the electrical system 597
11 1 3 Adjusting the crane cab seat and front control panel 598
Crane cab seat 598
Front control panel 599
11 1 4 Checking the safety equipment 600
Rated capacity limiter 600
Lifting limit switch 600
Emergency stopswitch 601
Seat contact switch 602
11 1 5 Earthing the load 603
11 1 6 Preheating hydraulic oil 604
Prerequisites 604
Preheating 604
11 1 7 Locking/unlocking the superstructure 605
Locking points 605
Lock the superstructure 606
Unlocking the superstructure 606
11 1 8 Switching the houselock on/off 607
Switching on thehouselock 607
Switching off the houselock 609
11 2 Standard slewing range type 611
11 2 1 Permissible slewing ranges and working positions 611
360 slewing range 611
Working position 0to 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 capacit 618
11 4 Operation of the rated capacity limiter 619
11 4 1 Switch on the RCL 620
Switching on 620
11 4 2 Enter rigging mode 622
Notes on Input 622
Enter the slewing range type 623
Entering individual components 624
Entering the RCLcode 630
11 4 3 Pre-selecting telescoping 630
11 4 4 Confirm the rigging mode and lifting capacity table 631
Slewing range type Standard 631
Slewing range type MAXbase 633
11 4 5 Checks before operating the crane 635
Monitoring menu 635
Checking the rigging mode 635
Hoist checking 637
11 4 6 Display during the crane operation 639
On the RCL display 639
On the CCSdisplay 643
11 4 7 RCL early warning 647
11 4 8 RCL shutdown 647
Shutdown due tooverload 647
11 4 9 Displaying the lifting capacity tables 649
Slewing range type Standard 649
Slewing range type MAXbase 651
11 4 10 RCL override – version A 653
Overview status display 653
When rigging 654
To raise the boom 655
In emergencies 656
11 4 11 RCL override – version B 657
11 4 12 Datalogger 658
Export data 658
Display the data 659
11 5 Crane operation with main boom 663
11 5 1 Checks during crane operation 663
Horizontal alignment 663
Safe distances 663
Checking the windspeed 664
11 5 2 Main hoist 665
Switching on themain hoist 666
Lifting and lowering 667
Maximum permissible hoist rope speed 668
Switching off themain hoist 668
11 5 3 Auxiliary hoist 669
Switching on the auxiliary hoist 669
Lifting and lowering 670
Maximum permissible hoist rope speed 671
Switching off the auxiliary hoist 671
11 5 4 Lifting limit switch and lowering limit switch 672
Lifting limit switch 672
Lowering limit switch 674
11 5 5 Derricking gear 675
Switching on the derricking gear 675
Raising and lowering 676
Maximum derricking speed 677
Re-enable raising function 677
Switching off the derricking gear 678
Lowering the main boom to ahorizontal position 678
11 5 6 Telescoping mechanism 679
Overview 681
Telescoping process 682
Assignment fordisplay 684
Fixed length, intermediate length, telescoping length 685
Telescoping 686
Telescoping sequence 686
Inspections prior to starting operations 687
Switching on thetelescoping mechanism 688
Function of the control lever 688
Switching off thetelescoping mechanism 690
Manual telescoping 691
Checking the initial position, 691
Unlocking the telescoping cylinder 693
Extending/retracting the telescoping cylinder 695
Lock telescoping cylinder 696
Unlocking the telescopic section 697
Telescoping the telescopic section 698
Locking the telescopic section 699
Locking the telescopic section for on-road driving 700
Telescoping with semi-automaton 700
Telescoping with pre-selection 702
11 5 7 High-speed mode 703
Derricking gear Telescoping mechanism 703
Hoists 703
11 5 8 Slewing gear 705
Slewing gear brake 705
Switching on the slewing gear 706
Releasing the slewing gear brake 706
Applying the slewing gear brake 706
Slewing 707
Permissible slewing speed 708
Braking the slewing movement 709
Slewing gear freewheel 709
Switching off the slewing gear 710
11 5 9 Switching the reduction of slewing speed on and off 711
Switching reduction off 711
11 5 10 Possible movement combinations 712
11 6 Settings and displays for crane operation 713
11 6 1 Inclining the crane cab 713
11 6 2 Idling speed, setting 714
11 6 3 Adjusting the wiper stroke interval of the windscreen wiper 714
11 6 4 Limiting the power unit speeds 715
11 6 5 Economy mode 716
Switching on 716
Ending/ switchingoff 718
11 6 6 Switching units of measure 718
11 6 7 Setting the characteristic curves for the control levers 719
11 6 8 Using the slewable spotlights 720
Manually swinging 721
Automatic load tracking 721
11 6 9 Overriding torque reduction 722
11 6 10 Displaying the operating hours 723
11 7 Working range limiter 725
11 7 1 viewing current settings 726
On the RCL dislay 726
In the CCS Startmenu 727
11 7 2 Opening the working range limiter menu 727
11 7 3 Enter limit values – for the overall height 728
11 7 4 Enter limit values – for the working radius 730
11 7 5 Enter limit values – for the slewing range 732
11 7 6 Enter limit values – for the hoist rope travel 735
11 7 7 Shutdown by working range limiter 737
11 8 Work break 739
11 8 1 In case of short work breaks 739
11 8 2 In case of work breaks of more than 8 hours 740
To secure the truck crane 740
11 9 Heating and air-conditioning system 741
11 9 1 Standard heating system 741
Switching on 741
Heating 741
Air distribution 742
Switching off 742
11 9 2 Air-conditioning system 743
Notes 743
Switching on/off 743
Cooling, automatic 744
Cooling, maximum 744
11 9 3 Auxiliary heater 745
Switching on 745
Setting the temperature 746
Setting the heating start/ heating duration 746
Switching heating start on/off 747
11 10 CraneSTAR system 748
11 10 1 Overview 748
11 10 2 Position of the components 748
12 Rigging work 749
12 1 Rigging work checklists for crane operation with themain boom 749
12 1 1 CHECKLIST: Rigging 749
12 1 2 CHECKLIST: Unrigging 755
12 2 Choice of a suitable positioning site 759
12 2 1 Determining the required load-bearing area 759
12 2 2 Safe distance from slopes and pits 762
12 2 3 Earthing the truck crane 763
12 2 4 Safe distance from overhead power lines 764
12 3 Rigging work after driving with a dolly 767
12 3 1 Switching off the boom floating position 767
12 3 2 Switching off the slewing gear freewheel 768
Before slewing 768
12 3 3 Switching off boom pre-tensioning 769
12 4 Connecting/disconnecting the hand-held control 771
12 5 Starting the engine for rigging 775
12 5 1 Starting/shutoff the engine – with the hand-held control 775
Prerequisites 775
Starting theengine 776
Turning off theengine 776
12 5 2 Starting/shutoff the engine – from the outrigger control units 777
Prerequisites 777
Starting theengine 777
Switch off theengine 777
12 6 Slewing range – only with the Standard slewing range type 779
12 6 1 Representation in the lifting capacity tables 779
12 6 2 Enabled outrigger spans 780
12 7 Outriggers – Overview – MAXbase slewing range type 781
12 7 1 Definitions 781
12 7 2 Representation in the lifting capacity tables 783
12 7 3 Enabled outrigger spans 784
12 8 Outrigger operation 789
12 8 1 CHECKLIST: Extending the outriggers 789
12 8 2 CHECKLIST: Retracting the outriggers 791
12 8 3 Preparing the truck crane 792
Driver’s cab 792
Crane cab 792
12 8 4 Setting the outrigger spans 794
For on-road driving 797
12 8 5 Extending/retracting outrigger beams 797
From the cranecab 798
From the controlunits 799
12 8 6 Moving the outrigger pads into operating/driving position 801
12 8 7 Enlarging the load-bearing area 803
12 8 8 Extending/retracting supporting cylinders 804
From the controlunits 805
From the cranecab 806
12 8 9 Levelling the truck crane on outriggers horizontally 808
Inclination indicators 808
Prerequisites 809
Manual alignment 810
Automatic alignment 810
12 8 10 Levelling the free-standing truck crane 812
12 8 11 Operating the axle raising system 814
12 8 12 Outrigger pressure display 816
12 9 Rigging/unrigging the counterweight 819
12 9 1 Information on rigging 819
When rigging 819
When unrigging 820
12 9 2 Counterweight sections 821
Version 1 821
Version 2 821
Version 3 822
12 9 3 Identification 823
12 9 4 Slinging points on the counterweight sections 824
12 9 5 CHECKLIST: Rigging the counterweight 825
12 9 6 CHECKLIST: Unrigging the counterweight 827
12 9 7 Assembling counterweight combination 828
Setting down the2 3 t base plate 829
Setting down the top couterweight section 829
Version 1 830
Version 2 838
Version 3 842
12 9 8 Counterweight hoist unit 850
Counterweight menu 850
Extending/retracting the lifting cylinders 851
Automatic mode rigging 853
Automatic mode unrigging 855
Cancel automatic mode 856
12 9 9 Removing/installing the counterweight on the turntable 857
Removing 857
Installing 858
12 9 10 Setting down counterweight for driving 859
Versions 1 and 3 859
Version 2 861
12 9 11 Slewing with rigged counterweight 861
12 10 Rigging work on the main boom 863
12 10 1 Hook block on the bumper 863
Picking up the hook block 863
Attaching the hook block 864
12 10 2 Hook block on a separate vehicle 865
Picking up the hook block 866
Setting down thehook block 866
12 10 3 Hook block, separable 868
Rigging for on- road driving 868
Rigging for crane operation 869
12 10 4 Hook block with ballast plates 870
Removing 870
Installing 871
Information on crane operation 871
12 10 5 Reeving and unreeving the hoist rope 872
Version A 872
Version B 873
Reeving the hoistrope 875
Unreeving hoistrope 879
12 10 6 Possible reevings on the main boom 880
With 6 head sheaves 880
With 8 head sheaves 883
With 9 head sheaves 886
12 10 7 Installing/removing the lifting limit switch 887
Installing the lifting limit switch 887
Removing the lifting limit switch 890
12 10 8 Locking/unlocking the lifting limit switch 892
Locking 892
Removing the lock 892
12 10 9 Anemometer and air traffic control light 893
Installing 893
Switching on/off 894
Removing 895
12 11 Other rigging work 897
12 11 1 Railings on the turntable 897
12 11 2 Folding the mirrors in and out, and adjusting them 898
12 11 3 Slinging points for personal protective equipment 899
12 11 4 Cameras for crane operation 900
Camera on mainboom 900
Camera on thehoists 903
Camera on the driver’s cab 903
Operating thecamera 904
12 11 5 Step at the crane cab 905
13 Driving with a rigged truck crane 907
13 1 Route 907
13 2 Permissible rigging modes and axle loads 908
Axle load table 908
13 2 1 To drive without a load 911
13 2 2 To drive with a load 911
13 2 3 Axle loads 912
13 3 Before driving the rigged truck crane 913
13 3 1 Check the tyre pressures and wind speed 913
13 3 2 Secure the superstructure against slewing 913
13 3 3 Putting the truck crane on the wheels – with Raise axle function 914
13 3 4 Putting the truck crane on the wheels – with the outriggers 916
13 4 Driving from the driver’s cab 919
13 4 1 Preparing to drive 919
Transmission 919
Switching on separate steering 919
Connections 919
13 4 2 Whilst driving 920
13 4 3 After driving 921
13 5 Driving from the crane cab 923
13 5 1 Preparing to drive 924
13 5 2 Opening/closing the driving menu 925
Opening the menu 925
Selecting the operating mode 925
Crane’s hydraulic system Driving mode 927
Closing menu 927
13 5 3 Steering 928
Switching on 928
Display and steering direction 928
Switching the steering direction 929
Displays whensteering 929
Separate steering 930
Normal steering mode 933
13 5 4 Operating the transmission 934
Selecting the transmission mode 934
13 5 5 Whilst driving 935
DMand RM transmission mode 935
Transmission mode D 935
Warning messages 935
13 5 6 Possible connections 936
Longitudinal/ transverse differential locks 936
13 5 7 After driving 938
14 Malfunctions during crane operation 939
14 1 Emergency stop switch 939
14 2 What to do when malfunctions occur during crane operation 940
The load can be set down 940
Load cannot besetdown 940
14 3 Warning and error messages 941
Program version 941
14 3 1 Warning messages on the CCS display 941
Meaning of the symbols 942
14 3 2 Error messages on the CCS display 946
14 3 3 Warning messages on the RCL display 948
14 4 Troubleshooting 953
14 4 1 Malfunctions on the engine 953
14 4 2 Malfunctions on the main hoist/auxiliary hoist 953
14 4 3 Malfunctions in the hoist cameras 955
14 4 4 Malfunctions in the main boom camera 955
14 4 5 Malfunctions on the derricking gear 956
14 4 6 Malfunctions in the telescoping mechanism 957
14 4 7 Malfunctions on the slewing gear 958
14 4 8 Malfunctions on the counterweight hoist unit 960
14 4 9 Malfunctions in the hydraulic system/hydraulic oil cooler 960
14 4 10 Malfunctions when operating with the hand-held control 961
14 4 11 Malfunctions when inclining the crane cab 961
14 4 12 Malfunctions when raising the axles 961
14 4 13 Malfunctions of the outriggers 962
14 4 14 Malfunctions on the turntable lock 962
14 4 15 Malfunctions on the CCS/RCL control units 963
14 4 16 Malfunctions when driving from the crane cab 963
14 4 17 Malfunctions on the CraneSTAR system 964
14 5 Emergency operations and programs 967
14 5 1 Mechanical emergency activation for retracting 968
Prior to the emergency operation, check 968
Procedure 968
Mechanical emergency activation 969
14 5 2 Telescoping emergency program 971
Telescoping emergency program menu 971
Determining the type of error 972
Error at the lengthindicator 973
Tables for approaching the locking points 977
14 5 3 Entering the current telescoping 979
14 5 4 Emergency operation with the hand-held control 981
To pre-select a power unit 982
Operating apowerunit 982
Stopping movements 983
Stopping movements in emergencies 984
Switch off theengine 984
14 5 5 Notes on slewing in emergency operation 984
For the Standard slewing range type 984
For the MAXbase slewing range type 986
14 5 6 Rotate for overridden slewing gear shutdown 987
14 6 Hydraulic emergency operation with the hand pump 989
14 6 2 Switching over the crane’s hydraulic system 990
14 6 3 Establishing the hydraulic circuits required 991
Releasing/ securing valves 991
Switching overvalves 992
For lowering 993
14 6 4 Performing emergency activation 994
14 6 5 After emergency activation 995
14 7 Hydraulic emergency operation acc to BGR159 997
14 7 1 Applications and function 997
14 7 2 CHECKLIST: Emergency operation 999
14 7 3 CHECKLIST: After emergency operation 1000
14 7 4 Connecting/removing transformer – for self-sufficiency 1001
Connecting 1001
Removing 1002
14 7 5 Switching emergency operation on/off 1003
14 7 6 Connecting/removing transformer – for external energy source 1004
14 7 7 Establishing the required hydraulic circuits 1005
Valves at the control panel 1005
For lifting/ lowering 1007
For slewing 1008
14 7 8 Performing emergency operation 1009
Slewing 1009
Derricking 1010
Lifting/lowering 1010
14 7 9 Emergency supply of another crane 1011
For emergency supply 1011
After emergency supply 1011
14 8 Fuses in the crane cab 1013
Information on changing fuses 1013
Index 1019
A 1021
B 1021
C 1022
D 1024
E 1026
F 1028
H 1028
I 1029
L 1029
M 1030
O 1031
P 1033
R 1033
S 1034
T 1035
V 1037
W 1037

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