Grove GMK5150L Crane Operation Manual (3302709) PDF

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Manitowoc Grove Crane GMK5150L Operating Manual 3302709  – PDF DOWNLOAD

The Manitowoc Grove GMK5150L Operating Manual (3302709) is a crucial PDF guide. Download for comprehensive insights into GMK5150L crane operation, featuring essential instructions for safe and efficient usage.

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Manitowoc Grove Crane GMK5150L Operating Manual 3302709  – PDF DOWNLOAD

Language : English
Pages :1048
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Grove Crane GMK5150L Operating Manual 3302709  – PDF DOWNLOAD

Operating manual 1
Correction sheet 3
Hook blocks – Change / Correction 3
Additional pages 7
MAXbase – Additional outrigger spans 7
Outrigger spans 9
Counterweight on the rear storage area 11
Driving from the crane cab 13
Telescoping emergency programe 15
Crane cab heating and air-conditioning system 17
Operation from the driver’s cab 17
Outrigger control units 19
Switching over the display between metre/feet and percent 19
Steering system warning 21
Additional functions 21
Table of contents 25
General 55
1 Overview 55
1 1 Accidents 55
1 2 Branch offices 57
1 2 1 Manitowoc Crane Care 57
1 2 2 Dealer list 57
1 3 Warranty specifications 57
1 4 Terms used 58
1 5 Technical data 61
1 5 1 Maximum lifting capacity (ASME B 30 5) 61
1 5 2 Dimensions and weights of the truck crane, axle loads 62
Dimensions 63
Weight and axleloads 63
1 5 3 Dimensions and weights of removable parts 64
Spare wheel 64
Outrigger 64
Main boom 64
Hook blocks andhook tackle 65
Auxiliary hoist 67
Counterweight parts 68
1 5 4 Carrier 71
Engine 71
Transmission 71
Transfer case 71
Axle lines 71
Steering 72
Tyres 72
Turning turningradii 72
Outrigger 73
Electrical system 74
Tool 74
Towing couplings 74
Driving speeds 74
Climbing ability 74
1 5 5 Superstructure 75
Main hoist 75
Auxiliary hoist 75
Slewing gears 75
Derricking gear 75
Main boom 76
Lattice extension 76
Operating speeds 76
1 6 Documentation supplied 77
1 6 1 Questions on documentation 78
1 7 Notes on the operating manual 79
1 7 1 What do the symbols used mean? 79
1 7 2 How is the operating manual structured? 81
Division 81
Structure of the chapters 81
Structure of thepages 82
1 7 3 How do I find the information I need? 83
Cross-references example 84
1 7 4 What information is available for operations planning? 86
1 8 Conversion table for US measuring units 87
1 9 Training – Information 89
1 10 Identification 90
1 11 EC Declaration of Conformity 92
2 Basic safety instructions 93
2 1 Intended use 93
2 1 1 Improper use 94
2 2 Organisational measures 95
2 3 Personnel qualifications 97
2 4 Safety instructions for driving the truck crane 98
2 5 Safety instructions for crane operation 99
2 6 Instructions on transporting persons 102
Equipment for lifting persons 102
Personnel 102
Operation 103
Truck crane 104
Driving 105
3 Operating elements for driving 105
3 1 Overview of the operating elements 105
3 1 1 On the outside of the truck crane 106
3 1 2 Driver’s cab 110
Front overview 110
Rear overview 112
Behind the cover 113
3 1 3 Steering column/steering wheel 114
3 1 4 Instrument panel 115
Left/right 115
Middle 116
3 1 5 Transmission operating elements 118
3 1 6 On-board computer 119
3 1 7 Tachograph 120
3 1 8 Heating and air-conditioning system 121
Standard 121
Auxiliary water heating system 122
Auxiliary air heater 123
3 1 9 CCS control unit 125
3 1 10 CCS – menu-dependent displays 126
3 1 11 CCS – Start menu 127
3 1 12 CCS – Overview menu groups 128
3 1 13 Carrier menu group 130
Suspension/level adjustment menu 131
Driving menu 132
3 1 14 Settings menu group 133
Set display brightness and date/time menu 134
Switch units menu 135
3 1 15 Menu group Information 136
Operating hoursmenu 137
Engine/transmission error menu 138
Crane operation error menu 139
3 1 16 Various controls menu group 140
3 1 17 Emergency operations menu group 141
3 1 18 Outrigger control units 142
3 2 Short description of the operating elements 143
3 2 1 Definition of information relating to directions of movement 144
Basic rule 144
3 2 2 General rules for buttons and symbols on the display 145
3 2 3 Engine 146
Steering column 146
On the steering wheel 146
Instrument panel 147
3 2 4 AdBlue system 148
Instrument panel 148
CCS display 149
3 2 5 Battery master switch 149
3 2 6 Electrical system 150
3 2 7 Crane control CCS 151
3 2 8 Transmission 153
Transmission control unit 153
Display, drivingmode 155
3 2 9 Reverse camera 156
3 2 10 BirdView system 270 157
3 2 11 Transfer case 159
3 2 12 Final drive 161
3 2 13 Brakes 162
Service brake 162
Additional brakes 162
Parking brake 163
3 2 14 Steering/separate steering 164
Instrument panel 164
CCS display 166
3 2 15 Suspension 168
CCS display 168
3 2 16 Lighting/windscreen wipers/horn 169
Steering column 169
Steering wheel 169
Instrument panel 169
CCS display 171
Roof 171
3 2 17 Level adjustment system 172
3 2 18 Tachograph/speedometer 174
Tachograph 174
Cover 174
Speedometer 174
3 2 19 Diagnostics 175
3 2 20 Push-up roof 175
3 2 21 On-board computer 176
3 2 22 Front flap 177
3 2 23 Windows and doors 178
Window winder 178
Doors 179
3 2 24 Access ladders and ladders 181
4 Starting the engine for driving / switching it off 185
4 1 Starting the engine from the driver’s cab 185
4 1 1 CHECKLIST: Starting the engine 185
4 1 2 CHECKLIST: At low temperatures 188
4 1 3 Filling up 189
Fuel tank 189
AdBlue tank 191
4 1 4 Checks before starting the engine 192
At the hydraulictank 192
Battery master switch 193
Checking the hand-held control 193
4 1 5 Switch the ignition on 193
4 1 6 Lamp test/equalisation of the switching states 194
Lamp test 194
Switching state alignment 194
4 1 7 Display – setting the brightness 195
4 1 8 Starting the engine 197
4 1 9 Checks after starting the engine 199
Start menu andon-board computer 199
Instrument panel 200
4 1 10 Setting the idling speed 201
4 2 Switch off the engine 202
4 2 1 At the ignition lock and with the outrigger control units 202
After switching off 202
4 2 2 Using the emergency stop switches 203
Resetting the emergency stopswitch 203
4 3 Air intake inhibitor 204
Opening the air intake inhibitor 204
5 Driving 205
5 1 Before driving 205
5 1 1 CHECKLIST: checks before on-road driving 205
5 1 2 Check the condition of the truck crane 211
Electrical system 211
Adjusting themirrors 211
Warning plates for vehicle width 213
Checking the vehicle height 213
Supply pressure 214
Parking brake 215
Third brake light 216
5 1 3 Adjusting the seat and the steering column 217
Adjusting the driver’s seat 217
Adjusting the passenger seat 218
Adjusting the steering column 219
5 1 4 Switching the suspension on/off 220
Open menu 220
Switching the suspension on 221
Switching the suspension off 221
5 1 5 Setting the tachograph 222
Prerequisites 222
In the event of malfunctions 222
Setting the tachograph 223
5 1 6 Setting the time 227
5 1 7 Displaying and resetting operating hours 228
5 2 Operating the transmission 229
5 2 1 Switching on 229
5 2 2 Switching the transmission to the neutral position 230
5 2 3 Selecting the direction of travel and starting gear 231
Selecting the driving direction 231
Selecting the starting gear  232
5 2 4 Changing the operating mode 233
Changing to automatic mode 233
Change to manualmode 233
5 2 5 Starting 234
5 2 6 Driving and changing gears 235
In automatic operating mode 235
In manual operating mode 236
5 2 7 Changing the driving direction 237
5 2 8 Stopping 237
Stopping for longer periods 237
5 2 9 On the roller type dynamometer 238
5 2 10 Preheating transmission 238
5 3 Driving the truck crane and switching it off 239
5 3 1 Checks whilst driving 239
Brakes 239
ABS system 239
Steering 240
Warning messages 240
Monitoring elements 241
5 3 2 Cruise control 242
Switching on 242
Switching off 243
5 3 3 Temposet 244
Switching on 244
Switching off 244
5 3 4 Driving downhill 245
Starting 245
Checks when driving downhill 246
Downshifting 246
Additional brakes 247
5 3 5 Driving uphill 248
Starting 248
Driving 248
5 3 6 Overriding torque reduction 249
5 3 7 Switching the truck crane off 250
Secure it against rolling away 250
When stationary for more than 8hours 251
5 3 8 Fold-up berth 252
5 4 Off-road driving 253
Adjustments to the transmission 253
Connections 253
Changing the vehicle level 253
Rocking the vehicle free and towing 253
5 4 1 Transfer case – switching the off-road gear on/off 254
5 4 2 Longitudinal and transverse differential locks 255
5 4 3 Operating the level adjustment system 257
Open menu 257
Setting the on-road level 258
Pre-selecting suspension struts 258
Changing the vehicle level 259
Viewing the current inclination 260
Exiting the menu 260
5 4 4 Freeing truck crane stuck in terrain 261
Rocking the truck crane free 261
Towing free forwards 262
Towing free totherear 262
5 5 Separate steering 263
5 5 1 Switching to separate steering 264
5 5 2 Switching to normal steering mode 267
5 5 3 Switching units of measure 268
5 6 Heating and air-conditioning system 269
5 6 1 Standard heating system 269
Switching on 269
Heating 269
Air distribution 270
Examples 271
Switching off 271
5 6 2 Air-conditioning system 272
Notes 272
Switching on/off 272
Cooling 273
Drying 273
5 6 3 Auxiliary water heating system 274
Preheating theengine 274
Preheating the driver’s cab 275
Switching on 275
Setting the date and time 277
Storing the heating start 278
5 6 4 Auxiliary air heater 280
Switching on 280
Setting the heating level 281
Setting the day and time 282
Setting the preselection time 282
Preselection timesDelete 284
Switching off 284
5 7 Radio 284
5 8 Towing a trailer 285
Effects on the axleloads 285
Coupling thetrailer 286
Connecting the supply lines 287
Removing supplylines 288
Uncoupling thetrailer 288
Checking the braking force 290
6 Driving modes and rigging for on-road driving 291
6 1 Driving modes 291
Information about the axle loads 291
6 1 1 How to use the tables 292
6 1 2 Table for a maximum axle load of 12 t (26,500 lbs) 293
Tyres 385/95 R25 293
Tyres 445/95 R25 294
Tyres 525/80 R25 295
6 1 3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs) 296
6 2 Weighing the truck crane 297
Axle groups 298
Weighing procedure 299
Evaluation 300
6 3 Rigging work for driving with a dolly 301
6 3 1 Switching on the slewing gear freewheel 302
6 3 2 Switching on the boom floating position 303
6 3 3 Switching on boom pre-tensioning 304
6 3 4 Raising/lowering the 3rd axle line for dolly operation 305
6 4 Rigging the main boom 307
Additional equipment required 307
6 4 1 CHECKLIST: Removing the main boom 308
Prerequisites 308
Checklist 308
6 4 2 CHECKLIST: Mounting the main boom 311
Prerequisites 311
Checklist 311
6 4 3 Disconnecting/connecting hydraulics/electrical 314
6 4 4 Derricking cylinder support 316
6 4 5 Slinging the main boom 316
Marking 316
Attach lifting gear 317
Removing the sling gear 318
6 4 6 Switching the pressure relief on/off 319
6 4 7 Retracting/fitting the derricking cylinder head pin 320
Operating the lifting device 320
Pulling the derricking cylinder head axle 320
Fitting the derricking cylinder head axle 321
6 4 8 Extending/retracting the boom pivot pin 322
Pulling out the pivot pin 322
Pushing the pivotpin in 324
6 4 9 Transporting the main boom 325
6 4 10 Securing/releasing the derricking cylinder 325
6 4 11 Aligning the connecting points 326
6 4 12 Inspections after main boom mounting 327
6 5 Rigging the auxiliary hoist 329
6 5 1 Slinging the auxiliary hoist 329
6 5 2 CHECKLIST: Installing the auxiliary hoist 330
6 5 3 CHECKLIST: Removing the auxiliary hoist 331
6 5 4 Making/breaking the connection between the auxiliary hoist and the turntable 332
6 5 5 Establishing/disconnecting the hydraulic connections 333
6 5 6 Disconnecting/establishing the electrical connection 334
6 5 7 Making/breaking the connection to the central lubrication 335
6 5 8 Transporting the auxiliary hoist 336
6 5 9 Check that the auxiliary hoist is functioning properly 337
Slewing direction 337
Slewing indicator 337
6 5 10 Rigging aid for the hoist rope 338
6 6 Installing/removing the outrigger beams 341
6 6 1 CHECKLIST: Removing the outrigger beams 342
6 6 2 CHECKLIST: Installing the outrigger beams 344
6 6 3 Centre of gravity data 346
6 6 4 Preparations – for removal 346
6 6 5 Preparations – on the truck crane 347
Prerequisites 347
6 6 6 Removing/attaching outrigger pads 348
Removing the outrigger pads 348
Attaching the outrigger pads 349
6 6 7 Disconnecting/establishing hydraulic connection 350
6 6 8 Disconnecting/establishing the electrical connection 351
6 6 9 Unscrewing/screwing in the spacers 352
Unscrewing 352
Screwing in 353
6 6 10 Disconnecting/establishing the connections to the supporting box 354
6 6 11 Pulling out/Inserting the outrigger beam 354
Extending the outrigger beam 354
Inserting the outrigger beam 356
6 6 12 Transporting the outrigger beams 358
6 6 13 Note on error messages with removed outrigger beams 358
7 Transport 359
7 1 Transport with transport vehicle 359
7 1 1 CHECKLIST: Checks before transport 360
7 1 2 Drive the truck crane on to the transport vehicle 362
Driving on 363
Lashing 363
7 2 Transport by ship 364
8 Malfunctions in driving mode 365
8 1 Emergency stop switch 365
8 2 Procedure during malfunctions 366
8 2 1 What to do when a malfunction occurs in road traffic 366
8 2 2 Procedure during engine malfunctions 367
8 2 3 Procedure during transmission malfunctions 368
8 3 Warning and error messages 369
8 3 1 Warning or malfunction messages on the instrument panel 369
Meaning of thelamps 369
8 3 2 Warning and malfunction messages on the on-board computer display 373
Messages 373
Symbols 374
8 3 3 Warning messages on the CCS display 377
Symbols in the display area 377
8 3 4 Error messages on the CCS display 381
Exiting the menu 382
Special error messages 382
8 4 Troubleshooting 383
8 4 1 Malfunctions on the engine 383
When operating with the dual tank 385
8 4 2 Faults on the Adblue system 385
8 4 3 Differential lock malfunctions 386
8 4 4 Transfer case malfunctions 386
8 4 5 Malfunctions in the transmission 387
8 4 6 Malfunctions of the steering 388
8 4 7 Malfunctions of the service brake 389
8 4 9 Malfunctions of the level adjustment system 390
8 4 10 Malfunctions in the hydraulic system/hydraulic oil cooler 390
8 5 Emergency operation and breakdown assistance 391
8 5 1 Starting the truck crane externally 391
8 5 2 Battery charger 392
Prerequisites 392
8 5 3 Towing the truck crane 393
In the case of engine/transmission damage 393
Longer towing distances 396
Tow starting 396
8 5 4 Wheel change 397
Removing a damaged wheel 398
On the spare wheel holder 398
Mounting a wheel 400
8 5 5 Inflating the tyres yourself 401
Connecting thefilling hose 401
Inflating the tyres 402
Remove the fillinghose 402
8 5 6 Emergency operation, steering 3rd and 4th axle lines 403
Performing emergency operation 404
After emergency operation 406
8 6 Tilting/lowering the driver’s cab 407
8 6 1 Prerequisites and information on tilting 407
8 6 2 Tilting and lowering the driver’s cab 408
Operating the hand pump 408
Tilting the driver’scab 409
Lowering the driver’s cab 410
8 7 Fuses on the carrier 413
Information on changing fuses 413
8 7 1 Fuses in the driver’s cab 414
8 7 2 Fuses in the battery box 420
Crane operation 421
9 Operating elements for crane operation 421
9 1 Overview of the operating elements 421
9 1 1 Exterior of the truck crane 422
9 1 2 Crane cab 426
Side panel 428
Crane cab, rear 430
9 1 3 Control panels 432
Left 432
Right 433
9 1 4 Control lever assignment 434
Version 1 434
Version 2 435
9 1 5 CCS control unit 436
9 1 6 Menu-independent displays 438
9 1 7 CCS – Start menu 439
RCL display 440
Display Slewing ranges/working radii 441
9 1 8 CCS – Overview menu groups 442
9 1 9 Superstructure menu group 446
Superstructure lock sub-menu 447
Counterweight menu 448
9 1 10 Menu group outrigger/driving 449
Outrigger menu 450
Outrigger cylinders menu 452
Driving menu 454
9 1 11 RCL/Telescoping menu group 457
Menu enter rigging mode/ telescope 458
Pre-selection telescoping menu 462
Lifting capacity tables menu 464
Telescoping semi- automation menu 465
Manual telescoping menu 466
9 1 12 Working range limiter menu group 467
Overall height menu 468
Working radius menu 469
Slewing angle menu 470
Hoist rope travel limitation menu 471
9 1 13 Information1 menu group 472
Hydraulic pressure and fuel consumption menu 473
9 1 14 Heating/Engine/Additional equipment menu group 474
Economy menu 475
Remote control menu 476
Heating/air- conditioning menu 477
Spotlights menu 478
9 1 15 Telescoping emergency program menu group 479
Telescoping emergency program menu 480
Unknown telescoping menu 482
9 1 16 Menu group, settings 483
Crane cab menu 484
Set display brightness and date/time menu 485
Switch units menu 486
Set control lever characteristic curve menu 487
Power unit speeds menu 488
9 1 17 Information2 menu group 489
Operating hoursmenu 490
Engine/ transmission error menu 491
Crane operation error menu 492
Program version menu 493
9 1 18 Various controls 495
9 1 19 RCL control unit 496
9 1 20 Menu-independent displays 497
9 1 21 RCL – menus 498
Monitoring menu 498
Lifting capacity tables menu 500
Datalogger menu 501
9 1 22 Hand-held control 503
9 1 23 Outriggers control units 505
Menu- independent buttons 505
Outrigger menu 506
Raise axle menu 508
9 2 Short description of the operating elements 509
9 2 1 Definition of information relating to directions of movement 509
Basic rule 509
9 2 2 General rules for buttons and symbols on the display 510
9 2 3 Engine 511
Side panel 511
Left control lever 511
Economy mode menu 512
9 2 4 AdBlue system 512
CCS display 512
9 2 5 Seat contact switch and dead man’s switch 514
9 2 6 Crane control CCS 515
9 2 7 Outrigger – crane cab 520
Control panels 520
CCS display 521
9 2 8 Outrigger control units 523
General information 523
Outrigger menu 524
9 2 9 Raise axle 526
9 2 10 Inclination indicators 528
9 2 11 Outrigger pressure displays 529
Outrigger menu 529
Outriggers controlunits 529
9 2 12 Anemometer displays 529
9 2 13 Counterweight menu 530
9 2 14 Main hoist 534
Control panels 534
CCS display 534
9 2 15 Auxiliary hoist 536
Control panels 536
CCS display 537
9 2 16 Slewing gear 538
Control panels 538
CCS display 539
9 2 17 Derricking gear 540
Control panels 540
CCS display 541
Side panel 541
9 2 18 Telescoping mechanism 542
Control panels 542
CCS display 543
Telescoping semi- automation menu 543
Manual telescoping menu 545
9 2 19 Hydraulic system 548
9 2 20 Superstructure lock/house lock menu 549
Superstructure lock 549
Houselock 551
9 2 21 Remote control 552
9 2 22 Rated capacity limiter (RCL) 553
CCS display 553
RCL display 562
RCL override – version A 563
RCL override – version B 564
9 2 23 Electrical system 565
9 2 24 Lighting, windscreen wiper/washing system 566
Lighting 566
Windscreen wiper/washing system 568
Horn 569
9 2 25 Hand-held control 570
Sockets for hand- held control 570
Engine control panel 571
Horn 571
9 2 26 Windows and doors 574
window 574
rear window 574
Crane cab door 575
9 2 27 Diagnostics 576
9 2 28 Other 576
9 3 Short description of the operating elements – driving from the crane cab 577
9 3 1 Driving menu 577
9 3 2 Transmission 579
9 3 3 Final drive 581
9 3 4 Brakes 582
CCS display 582
Side panel fromabove 582
9 3 5 Steering 583
CCS display 584
Control panels 586
10 Starting/switching off the engine – for crane operation 587
10 1 When starting the engine for the first time in the day 587
10 2 Starting the engine – from the crane cab 589
10 2 1 Check the fuel level and AdBlue level 589
Fuel 589
AdBlue 589
10 2 2 Checks before starting the engine 590
Checks on the carrier 590
Checking the hand-held control 590
At the hydraulic tank 590
10 2 3 Switching the ignition on 591
10 2 4 Comparison of switching states 592
10 2 5 Display – setting the brightness 592
10 2 6 Starting the engine 593
10 2 7 Checks after starting the engine 594
10 2 8 Setting the idling speed 595
10 3 Starting the engine – with the hand-held control 596
10 4 Switch off the engine 597
10 4 1 At the ignition lock and with hand-held control 597
After switching off 597
10 4 2 With the idling button 597
10 4 3 Using the emergency stop switches 598
Emergency stop switch, resetting 598
11 Crane operation 599
11 1 Before operating the crane 599
11 1 1 CHECKLIST: Checks before operating the crane 599
11 1 2 Check the condition of the truck crane 603
Fuel tank auxiliary heater 603
Visual inspection 603
Checking the position of the hoist ropes 604
Checking the electrical system 605
11 1 3 Adjusting the crane cab seat and front control panel 606
Crane cab seat 606
Front control panel 607
11 1 4 Checking the safety equipment 608
Rated capacity limiter 608
Lifting limit switch 608
Emergency stopswitch 609
Seat contact switch 610
11 1 5 Earthing the load 611
11 1 6 Preheating hydraulic oil 612
Prerequisites 612
Preheating 612
11 1 7 Locking/unlocking the superstructure 613
Locking points 613
Lock the superstructure 614
Unlocking the superstructure 614
11 1 8 Switching the houselock on/off 615
Switching on thehouselock 615
Switching off the houselock 617
11 2 Standard slewing range type 619
11 2 1 Permissible slewing ranges and working positions 619
360 slewing range 619
Working position 0to the rear 619
180 to the front rigging position 619
11 3 MAXbase slewing range type 621
11 3 1 Specifications in the lifting capacity tables 622
11 3 2 Enabled slewing ranges 623
11 3 3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacit 626
11 4 Operation of the rated capacity limiter 627
11 4 1 Switch on the RCL 628
Switching on 628
11 4 2 Enter rigging mode 630
Notes on Input 630
Enter the slewing range type 631
Entering individual components 632
Entering the RCLcode 638
11 4 3 Pre-selecting telescoping 638
11 4 4 Confirm the rigging mode and lifting capacity table 639
Slewing range type Standard 639
Slewing range type MAXbase 641
11 4 5 Checks before operating the crane 643
Monitoring menu 643
Checking the rigging mode 643
Hoist checking 645
11 4 6 Display during the crane operation 647
On the RCL display 647
On the CCSdisplay 651
11 4 7 RCL early warning 655
11 4 8 RCL shutdown 655
Shutdown due tooverload 655
11 4 9 Displaying the lifting capacity tables 657
Slewing range type Standard 657
Slewing range type MAXbase 659
11 4 10 RCL override – version A 661
Overview status display 661
When rigging 662
To raise the boom 663
In emergencies 664
11 4 11 RCL override – version B 665
11 4 12 Datalogger 666
Export data 666
Display the data 667
11 5 Crane operation with main boom 671
11 5 1 Checks during crane operation 671
Horizontal alignment 671
Safe distances 671
Checking the windspeed 672
11 5 2 Main hoist 673
Switching on themain hoist 674
Lifting and lowering 675
Maximum permissible hoist rope speed 676
Switching off themain hoist 676
11 5 3 Auxiliary hoist 677
Switching on the auxiliary hoist 677
Lifting and lowering 678
Maximum permissible hoist rope speed 679
Switching off the auxiliary hoist 679
11 5 4 Lifting limit switch and lowering limit switch 680
Lifting limit switch 680
Lowering limit switch 682
11 5 5 Derricking gear 683
Switching on the derricking gear 683
Raising and lowering 684
Maximum derricking speed 685
Re-enable raising function 685
Switching off the derricking gear 686
Lowering the main boom to ahorizontal position 686
11 5 6 Telescoping mechanism 687
Overview 689
Telescoping process 690
Assignment fordisplay 692
Fixed length, intermediate length, telescoping length 693
Telescoping 694
Telescoping sequence 694
Inspections prior to starting operations 695
Switching on thetelescoping mechanism 696
Function of the control lever 696
Switching off thetelescoping mechanism 698
Manual telescoping 699
Checking the initial position, 699
Unlocking the telescoping cylinder 701
Extending/retracting the telescoping cylinder 703
Lock telescoping cylinder 704
Unlocking the telescopic section 705
Telescoping the telescopic section 706
Locking the telescopic section 707
Locking the telescopic section for on-road driving 708
Telescoping with semi-automaton 708
Telescoping with pre-selection 710
11 5 7 High-speed mode 711
Derricking gear Telescoping mechanism 711
Hoists 711
11 5 8 Slewing gear 713
Slewing gear brake 713
Switching on the slewing gear 714
Releasing the slewing gear brake 714
Applying the slewing gear brake 714
Slewing 715
Permissible slewing speed 716
Braking the slewing movement 717
Slewing gear freewheel 717
Switching off the slewing gear 718
11 5 9 Switching the reduction of slewing speed on and off 719
Switching reduction off 719
11 5 10 Possible movement combinations 720
11 6 Settings and displays for crane operation 721
11 6 1 Inclining the crane cab 721
11 6 2 Idling speed, setting 722
11 6 3 Adjusting the wiper stroke interval of the windscreen wiper 722
11 6 4 Limiting the power unit speeds 723
11 6 5 Economy mode 724
Switching on 724
Ending/ switchingoff 726
11 6 6 Switching units of measure 726
11 6 7 Setting the characteristic curves for the control levers 727
11 6 8 Using the slewable spotlights 728
Manually swinging 729
Automatic load tracking 729
11 6 9 Overriding torque reduction 730
11 6 10 Displaying the operating hours 731
11 7 Working range limiter 733
11 7 1 viewing current settings 734
On the RCL dislay 734
In the CCS Startmenu 735
11 7 2 Opening the working range limiter menu 735
11 7 3 Enter limit values – for the overall height 736
11 7 4 Enter limit values – for the working radius 738
11 7 5 Enter limit values – for the slewing range 740
11 7 6 Enter limit values – for the hoist rope travel 743
11 7 7 Shutdown by working range limiter 745
11 8 Work break 747
11 8 1 In case of short work breaks 747
11 8 2 In case of work breaks of more than 8 hours 748
To secure the truck crane 748
11 9 Heating and air-conditioning system 749
11 9 1 Standard heating system 749
Switching on 749
Heating 749
Air distribution 750
Switching off 750
11 9 2 Air-conditioning system 751
Notes 751
Switching on/off 751
Cooling, automatic 752
Cooling, maximum 752
11 9 3 Auxiliary heater 753
Switching on 753
Setting the temperature 754
Setting the heating start/ heating duration 754
Switching heating start on/off 755
11 10 CraneSTAR system 756
11 10 1 Overview 756
11 10 2 Position of the components 756
12 Rigging work 757
12 1 Rigging work checklists for crane operation with themain boom 757
12 1 1 CHECKLIST: Rigging 757
12 1 2 CHECKLIST: Unrigging 763
12 2 Choice of a suitable positioning site 767
12 2 1 Determining the required load-bearing area 767
12 2 2 Safe distance from slopes and pits 770
12 2 3 Earthing the truck crane 771
12 2 4 Safe distance from overhead power lines 772
12 3 Rigging work after driving with a dolly 775
12 3 1 Switching off the boom floating position 775
12 3 2 Switching off the slewing gear freewheel 776
Before slewing 776
12 3 3 Switching off boom pre-tensioning 777
12 4 Connecting/disconnecting the hand-held control 779
12 5 Starting the engine for rigging 783
12 5 1 Starting/shutoff the engine – with the hand-held control 783
Prerequisites 783
Starting theengine 784
Turning off theengine 784
12 5 2 Starting/shutoff the engine – from the outrigger control units 785
Prerequisites 785
Starting theengine 785
Switch off theengine 785
12 6 Slewing range – only with the Standard slewing range type 787
12 6 1 Representation in the lifting capacity tables 787
12 6 2 Enabled outrigger spans 788
12 7 Outriggers – Overview – MAXbase slewing range type 789
12 7 1 Definitions 789
12 7 2 Representation in the lifting capacity tables 791
12 7 3 Enabled outrigger spans 792
12 8 Outrigger operation 797
12 8 1 CHECKLIST: Extending the outriggers 797
12 8 2 CHECKLIST: Retracting the outriggers 799
12 8 3 Preparing the truck crane 800
Driver’s cab 800
Crane cab 800
12 8 4 Setting the outrigger spans 802
For on-road driving 805
12 8 5 Extending/retracting outrigger beams 805
From the cranecab 806
From the controlunits 807
12 8 6 Moving the outrigger pads into operating/driving position 809
12 8 7 Enlarging the load-bearing area 811
12 8 8 Extending/retracting supporting cylinders 812
From the controlunits 813
From the cranecab 814
12 8 9 Levelling the truck crane on outriggers horizontally 816
Inclination indicators 816
Prerequisites 817
Manual alignment 818
Automatic alignment 818
12 8 10 Levelling the free-standing truck crane 820
12 8 11 Operating the axle raising system 822
12 8 12 Outrigger pressure display 824
12 9 Rigging/unrigging the counterweight 827
12 9 1 Information on rigging 827
When rigging 827
When unrigging 828
12 9 2 Counterweight sections 829
Version 1 829
Version 2 829
Version 3 830
12 9 3 Identification 831
12 9 4 Slinging points on the counterweight sections 832
12 9 5 CHECKLIST: Rigging the counterweight 833
12 9 6 CHECKLIST: Unrigging the counterweight 835
12 9 7 Assembling counterweight combination 836
Setting down the2 3 t base plate 837
Setting down the top couterweight section 837
Version 1 838
Version 2 846
Version 3 850
12 9 8 Counterweight hoist unit 858
Counterweight menu 858
Extending/retracting the lifting cylinders 859
Automatic mode rigging 861
Automatic mode unrigging 863
Cancel automatic mode 864
12 9 9 Removing/installing the counterweight on the turntable 865
Removing 865
Installing 866
12 9 10 Setting down counterweight for driving 867
Versions 1 and 3 867
Version 2 869
12 9 11 Slewing with rigged counterweight 869
12 10 Rigging work on the main boom 871
12 10 1 Hook block on the bumper 871
Picking up the hook block 871
Attaching the hook block 872
12 10 2 Hook block on a separate vehicle 873
Picking up the hook block 874
Setting down thehook block 874
12 10 3 Hook block, separable 876
Rigging for on- road driving 876
Rigging for crane operation 877
12 10 4 Hook block with ballast plates 878
Removing 878
Installing 879
Information on crane operation 879
12 10 5 Reeving and unreeving the hoist rope 880
Version A 880
Version B 881
Reeving the hoistrope 883
Unreeving hoistrope 887
12 10 6 Possible reevings on the main boom 888
With 6 head sheaves 888
With 8 head sheaves 891
With 9 head sheaves 894
12 10 7 Installing/removing the lifting limit switch 895
Installing the lifting limit switch 895
Removing the lifting limit switch 898
12 10 8 Locking/unlocking the lifting limit switch 900
Locking 900
Removing the lock 900
12 10 9 Anemometer and air traffic control light 901
Installing 901
Switching on/off 902
Removing 903
12 11 Other rigging work 905
12 11 1 Railings on the turntable 905
12 11 2 Folding the mirrors in and out, and adjusting them 906
12 11 3 Slinging points for personal protective equipment 907
12 11 4 Cameras for crane operation 908
Camera on mainboom 908
Camera on thehoists 911
Camera on the driver’s cab 911
Operating thecamera 912
12 11 5 Step at the crane cab 913
13 Driving with a rigged truck crane 915
13 1 Route 915
13 2 Permissible rigging modes and axle loads 916
Axle load table 916
13 2 1 To drive without a load 919
13 2 2 To drive with a load 919
13 2 3 Axle loads 920
13 3 Before driving the rigged truck crane 921
13 3 1 Check the tyre pressures and wind speed 921
13 3 2 Secure the superstructure against slewing 921
13 3 3 Putting the truck crane on the wheels – with Raise axle function 922
13 3 4 Putting the truck crane on the wheels – with the outriggers 924
13 4 Driving from the driver’s cab 927
13 4 1 Preparing to drive 927
Transmission 927
Switching on separate steering 927
Connections 927
13 4 2 Whilst driving 928
13 4 3 After driving 929
13 5 Driving from the crane cab 931
13 5 1 Preparing to drive 932
13 5 2 Opening/closing the driving menu 933
Opening the menu 933
Selecting the operating mode 933
Crane’s hydraulic system Driving mode 935
Closing menu 935
13 5 3 Steering 936
Switching on 936
Display and steering direction 936
Switching the steering direction 937
Displays whensteering 937
Separate steering 938
Normal steering mode 941
13 5 4 Operating the transmission 942
Selecting the transmission mode 942
13 5 5 Whilst driving 943
DMand RM transmission mode 943
Transmission mode D 943
Warning messages 943
13 5 6 Possible connections 944
Longitudinal/ transverse differential locks 944
13 5 7 After driving 946
14 Malfunctions during crane operation 947
14 1 Emergency stop switch 947
14 2 What to do when malfunctions occur during crane operation 948
The load can be set down 948
Load cannot besetdown 948
14 3 Warning and error messages 949
Program version 949
14 3 1 Warning messages on the CCS display 949
Meaning of the symbols 950
14 3 2 Error messages on the CCS display 954
14 3 3 Warning messages on the RCL display 956
14 4 Troubleshooting 961
14 4 1 Malfunctions on the engine 961
14 4 2 Malfunctions on the main hoist/auxiliary hoist 961
14 4 3 Malfunctions in the hoist cameras 963
14 4 4 Malfunctions in the main boom camera 963
14 4 5 Malfunctions on the derricking gear 964
14 4 6 Malfunctions in the telescoping mechanism 965
14 4 7 Malfunctions on the slewing gear 966
14 4 8 Malfunctions on the counterweight hoist unit 968
14 4 9 Malfunctions in the hydraulic system/hydraulic oil cooler 968
14 4 10 Malfunctions when operating with the hand-held control 969
14 4 11 Malfunctions when inclining the crane cab 969
14 4 12 Malfunctions when raising the axles 969
14 4 13 Malfunctions of the outriggers 970
14 4 14 Malfunctions on the turntable lock 970
14 4 15 Malfunctions on the CCS/RCL control units 971
14 4 16 Malfunctions when driving from the crane cab 971
14 4 17 Malfunctions on the CraneSTAR system 972
14 5 Emergency operations and programs 975
14 5 1 Mechanical emergency activation for retracting 976
Prior to the emergency operation, check 976
Procedure 976
Mechanical emergency activation 977
14 5 2 Telescoping emergency program 979
Telescoping emergency program menu 979
Determining the type of error 980
Error at the lengthindicator 981
Tables for approaching the locking points 985
14 5 3 Entering the current telescoping 987
14 5 4 Emergency operation with the hand-held control 989
To pre-select a power unit 990
Operating apowerunit 990
Stopping movements 991
Stopping movements in emergencies 992
Switch off theengine 992
14 5 5 Notes on slewing in emergency operation 992
For the Standard slewing range type 992
For the MAXbase slewing range type 994
14 5 6 Rotate for overridden slewing gear shutdown 995
14 6 Hydraulic emergency operation with the hand pump 997
14 6 2 Switching over the crane’s hydraulic system 998
14 6 3 Establishing the hydraulic circuits required 999
Releasing/ securing valves 999
Switching overvalves 1000
For lowering 1001
14 6 4 Performing emergency activation 1002
14 6 5 After emergency activation 1003
14 7 Hydraulic emergency operation acc to BGR159 1005
14 7 1 Applications and function 1005
14 7 2 CHECKLIST: Emergency operation 1007
14 7 3 CHECKLIST: After emergency operation 1008
14 7 4 Connecting/removing transformer – for self-sufficiency 1009
Connecting 1009
Removing 1010
14 7 5 Switching emergency operation on/off 1011
14 7 6 Connecting/removing transformer – for external energy source 1012
14 7 7 Establishing the required hydraulic circuits 1013
Valves at the control panel 1013
For lifting/ lowering 1015
For slewing 1016
14 7 8 Performing emergency operation 1017
Slewing 1017
Derricking 1018
Lifting/lowering 1018
14 7 9 Emergency supply of another crane 1019
For emergency supply 1019
After emergency supply 1019
14 8 Fuses in the crane cab 1021
Information on changing fuses 1021
Index 1027
A 1029
B 1029
C 1030
D 1032
E 1034
F 1036
H 1036
I 1037
L 1037
M 1038
O 1039
P 1041
R 1041
S 1042
T 1043
V 1045
W 1045

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S.M