Manitowoc Grove Crane GMK5150L Operating Manual 3302709 PDF

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Manitowoc Grove Crane GMK5150L Operating Manual 3302709  – PDF DOWNLOAD

The Manitowoc Grove Crane GMK5150L Operating Manual (3302709) is an essential PDF guide. Download for detailed insights into GMK5150L operation, covering crucial instructions and guidelines for safe and efficient crane usage.

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Manitowoc Grove Crane GMK5150L Operating Manual 3302709  – PDF DOWNLOAD

Language : English
Pages : 1032
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Grove Crane GMK5150L Operating Manual 3302709  – PDF DOWNLOAD

Operating manual 1
Additional pages 5
Outrigger spans 3
Driving from the crane cab 5
Table of contents 9
General 39
1 Overview 39
1 1 Accidents 39
1 2 Branch offices 41
1 2 1 Manitowoc Crane Care 41
1 2 2 Dealer list 41
1 3 Warranty specifications 41
1 4 Terms used 42
1 5 Technical data 45
1 5 1 Maximum lifting capacity (ASME B 30 5) 45
1 5 2 Dimensions and weights of the truck crane, axle loads 46
Dimensions 47
Weight and axleloads 47
1 5 3 Dimensions and weights of removable parts 48
Spare wheel 48
Outrigger 48
Main boom 48
Hook blocks andhook tackle 49
Auxiliary hoist 51
Counterweight parts 52
1 5 4 Carrier 55
Engine 55
Transmission 55
Transfer case 55
Axle lines 55
Steering 56
Tyres 56
Turning turningradii 56
Outrigger 57
Electrical system 58
Tool 58
Towing couplings 58
Driving speeds 58
Climbing ability 58
1 5 5 Superstructure 59
Main hoist 59
Auxiliary hoist 59
Slewing gears 59
Derricking gear 59
Main boom 60
Lattice extension 60
Operating speeds 60
1 6 Documentation supplied 61
1 6 1 Questions on documentation 62
1 7 Notes on the operating manual 63
1 7 1 What do the symbols used mean? 63
1 7 2 How is the operating manual structured? 65
Division 65
Structure of the chapters 65
Structure of thepages 66
1 7 3 How do I find the information I need? 67
Cross-references example 68
1 7 4 What information is available for operations planning? 70
1 8 Conversion table for US measuring units 71
1 9 Training – Information 73
1 10 Identification 74
1 11 EC Declaration of Conformity 76
2 Basic safety instructions 77
2 1 Intended use 77
2 1 1 Improper use 78
2 2 Organisational measures 79
2 3 Personnel qualifications 81
2 4 Safety instructions for driving the truck crane 82
2 5 Safety instructions for crane operation 83
2 6 Instructions on transporting persons 86
Equipment for lifting persons 86
Personnel 86
Operation 87
Truck crane 88
Driving 89
3 Operating elements for driving 89
3 1 Overview of the operating elements 89
3 1 1 On the outside of the truck crane 90
3 1 2 Driver’s cab 94
Front overview 94
Rear overview 96
Behind the cover 97
3 1 3 Steering column/steering wheel 98
3 1 4 Instrument panel 99
Left/right 99
Middle 100
3 1 5 Transmission operating elements 102
3 1 6 On-board computer 103
3 1 7 Tachograph 104
3 1 8 Heating and air-conditioning system 105
Standard 105
Auxiliary water heating system 106
Auxiliary air heater 107
3 1 9 CCS control unit 109
3 1 10 CCS – menu-dependent displays 110
3 1 11 CCS – Start menu 111
3 1 12 CCS – Overview menu groups 112
3 1 13 Carrier menu group 114
Suspension/level adjustment menu 115
Driving menu 116
3 1 14 Settings menu group 117
Set display brightness and date/time menu 118
Switch units menu 119
3 1 15 Menu group Information 120
Operating hoursmenu 121
Engine/transmission error menu 122
Crane operation error menu 123
3 1 16 Various controls menu group 124
3 1 17 Emergency operations menu group 125
3 1 18 Outrigger control units 126
3 2 Short description of the operating elements 127
3 2 1 Definition of information relating to directions of movement 128
Basic rule 128
3 2 2 General rules for buttons and symbols on the display 129
3 2 3 Engine 130
Steering column 130
On the steering wheel 130
Instrument panel 131
3 2 4 AdBlue system 132
Instrument panel 132
CCS display 133
3 2 5 Battery master switch 133
3 2 6 Electrical system 134
3 2 7 Crane control CCS 135
3 2 8 Transmission 137
Transmission control unit 137
Display, drivingmode 139
3 2 9 Reverse camera 140
3 2 10 BirdView system 270 141
3 2 11 Transfer case 143
3 2 12 Final drive 145
3 2 13 Brakes 146
Service brake 146
Additional brakes 146
Parking brake 147
3 2 14 Steering/separate steering 148
Instrument panel 148
CCS display 150
3 2 15 Suspension 152
CCS display 152
3 2 16 Lighting/windscreen wipers/horn 153
Steering column 153
Steering wheel 153
Instrument panel 153
CCS display 155
Roof 155
3 2 17 Level adjustment system 156
3 2 18 Tachograph/speedometer 158
Tachograph 158
Cover 158
Speedometer 158
3 2 19 Diagnostics 159
3 2 20 Push-up roof 159
3 2 21 On-board computer 160
3 2 22 Front flap 161
3 2 23 Windows and doors 162
Window winder 162
Doors 163
3 2 24 Access ladders and ladders 165
4 Starting the engine for driving / switching it off 169
4 1 Starting the engine from the driver’s cab 169
4 1 1 CHECKLIST: Starting the engine 169
4 1 2 CHECKLIST: At low temperatures 172
4 1 3 Filling up 173
Fuel tank 173
AdBlue tank 175
4 1 4 Checks before starting the engine 176
At the hydraulictank 176
Battery master switch 177
Checking the hand-held control 177
4 1 5 Switch the ignition on 177
4 1 6 Lamp test/equalisation of the switching states 178
Lamp test 178
Switching state alignment 178
4 1 7 Display – setting the brightness 179
4 1 8 Starting the engine 181
4 1 9 Checks after starting the engine 183
Start menu andon-board computer 183
Instrument panel 184
4 1 10 Setting the idling speed 185
4 2 Switch off the engine 186
4 2 1 At the ignition lock and with the outrigger control units 186
After switching off 186
4 2 2 Using the emergency stop switches 187
Resetting the emergency stopswitch 187
4 3 Air intake inhibitor 188
Opening the air intake inhibitor 188
5 Driving 189
5 1 Before driving 189
5 1 1 CHECKLIST: checks before on-road driving 189
5 1 2 Check the condition of the truck crane 195
Electrical system 195
Adjusting themirrors 195
Warning plates for vehicle width 197
Checking the vehicle height 197
Supply pressure 198
Parking brake 199
Third brake light 200
5 1 3 Adjusting the seat and the steering column 201
Adjusting the driver’s seat 201
Adjusting the passenger seat 202
Adjusting the steering column 203
5 1 4 Switching the suspension on/off 204
Open menu 204
Switching the suspension on 205
Switching the suspension off 205
5 1 5 Setting the tachograph 206
Prerequisites 206
In the event of malfunctions 206
Setting the tachograph 207
5 1 6 Setting the time 211
5 1 7 Displaying and resetting operating hours 212
5 2 Operating the transmission 213
5 2 1 Switching on 213
5 2 2 Switching the transmission to the neutral position 214
5 2 3 Selecting the direction of travel and starting gear 215
Selecting the driving direction 215
Selecting the starting gear  216
5 2 4 Changing the operating mode 217
Changing to automatic mode 217
Change to manualmode 217
5 2 5 Starting 218
5 2 6 Driving and changing gears 219
In automatic operating mode 219
In manual operating mode 220
5 2 7 Changing the driving direction 221
5 2 8 Stopping 221
Stopping for longer periods 221
5 2 9 On the roller type dynamometer 222
5 2 10 Preheating transmission 222
5 3 Driving the truck crane and switching it off 223
5 3 1 Checks whilst driving 223
Brakes 223
ABS system 223
Steering 224
Warning messages 224
Monitoring elements 225
5 3 2 Cruise control 226
Switching on 226
Switching off 227
5 3 3 Temposet 228
Switching on 228
Switching off 228
5 3 4 Driving downhill 229
Starting 229
Checks when driving downhill 230
Downshifting 230
Additional brakes 231
5 3 5 Driving uphill 232
Starting 232
Driving 232
5 3 6 Overriding torque reduction 233
5 3 7 Switching the truck crane off 234
Secure it against rolling away 234
When stationary for more than 8hours 235
5 3 8 Fold-up berth 236
5 4 Off-road driving 237
Adjustments to the transmission 237
Connections 237
Changing the vehicle level 237
Rocking the vehicle free and towing 237
5 4 1 Transfer case – switching the off-road gear on/off 238
5 4 2 Longitudinal and transverse differential locks 239
5 4 3 Operating the level adjustment system 241
Open menu 241
Setting the on-road level 242
Pre-selecting suspension struts 242
Changing the vehicle level 243
Viewing the current inclination 244
Exiting the menu 244
5 4 4 Freeing truck crane stuck in terrain 245
Rocking the truck crane free 245
Towing free forwards 246
Towing free totherear 246
5 5 Separate steering 247
5 5 1 Switching to separate steering 248
5 5 2 Switching to normal steering mode 251
5 5 3 Switching units of measure 252
5 6 Heating and air-conditioning system 253
5 6 1 Standard heating system 253
Switching on 253
Heating 253
Air distribution 254
Examples 255
Switching off 255
5 6 2 Air-conditioning system 256
Notes 256
Switching on/off 256
Cooling 257
Drying 257
5 6 3 Auxiliary water heating system 258
Preheating theengine 258
Preheating the driver’s cab 259
Switching on 259
Setting the date and time 261
Storing the heating start 262
5 6 4 Auxiliary air heater 264
Switching on 264
Setting the heating level 265
Setting the day and time 266
Setting the preselection time 266
Preselection timesDelete 268
Switching off 268
5 7 Radio 268
5 8 Towing a trailer 269
Effects on the axleloads 269
Coupling thetrailer 270
Connecting the supply lines 271
Removing supplylines 272
Uncoupling thetrailer 272
Checking the braking force 274
6 Driving modes and rigging for on-road driving 275
6 1 Driving modes 275
Information about the axle loads 275
6 1 1 How to use the tables 276
6 1 2 Table for a maximum axle load of 12 t (26,500 lbs) 277
Tyres 385/95 R25 277
Tyres 445/95 R25 278
Tyres 525/80 R25 279
6 1 3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs) 280
6 2 Weighing the truck crane 281
Axle groups 282
Weighing procedure 283
Evaluation 284
6 3 Rigging work for driving with a dolly 285
6 3 1 Switching on the slewing gear freewheel 286
6 3 2 Switching on the boom floating position 287
6 3 3 Switching on boom pre-tensioning 288
6 3 4 Raising/lowering the 3rd axle line for dolly operation 289
6 4 Rigging the main boom 291
Additional equipment required 291
6 4 1 CHECKLIST: Removing the main boom 292
Prerequisites 292
Checklist 292
6 4 2 CHECKLIST: Mounting the main boom 295
Prerequisites 295
Checklist 295
6 4 3 Disconnecting/connecting hydraulics/electrical 298
6 4 4 Derricking cylinder support 300
6 4 5 Slinging the main boom 300
Marking 300
Attach lifting gear 301
Removing the sling gear 302
6 4 6 Switching the pressure relief on/off 303
6 4 7 Retracting/fitting the derricking cylinder head pin 304
Operating the lifting device 304
Pulling the derricking cylinder head axle 304
Fitting the derricking cylinder head axle 305
6 4 8 Extending/retracting the boom pivot pin 306
Pulling out the pivot pin 306
Pushing the pivotpin in 308
6 4 9 Transporting the main boom 309
6 4 10 Securing/releasing the derricking cylinder 309
6 4 11 Aligning the connecting points 310
6 4 12 Inspections after main boom mounting 311
6 5 Rigging the auxiliary hoist 313
6 5 1 Slinging the auxiliary hoist 313
6 5 2 CHECKLIST: Installing the auxiliary hoist 314
6 5 3 CHECKLIST: Removing the auxiliary hoist 315
6 5 4 Making/breaking the connection between the auxiliary hoist and the turntable 316
6 5 5 Establishing/disconnecting the hydraulic connections 317
6 5 6 Disconnecting/establishing the electrical connection 318
6 5 7 Making/breaking the connection to the central lubrication 319
6 5 8 Transporting the auxiliary hoist 320
6 5 9 Check that the auxiliary hoist is functioning properly 321
Slewing direction 321
Slewing indicator 321
6 5 10 Rigging aid for the hoist rope 322
6 6 Installing/removing the outrigger beams 325
6 6 1 CHECKLIST: Removing the outrigger beams 326
6 6 2 CHECKLIST: Installing the outrigger beams 328
6 6 3 Centre of gravity data 330
6 6 4 Preparations – for removal 330
6 6 5 Preparations – on the truck crane 331
Prerequisites 331
6 6 6 Removing/attaching outrigger pads 332
Removing the outrigger pads 332
Attaching the outrigger pads 333
6 6 7 Disconnecting/establishing hydraulic connection 334
6 6 8 Disconnecting/establishing the electrical connection 335
6 6 9 Unscrewing/screwing in the spacers 336
Unscrewing 336
Screwing in 337
6 6 10 Disconnecting/establishing the connections to the supporting box 338
6 6 11 Pulling out/Inserting the outrigger beam 338
Extending the outrigger beam 338
Inserting the outrigger beam 340
6 6 12 Transporting the outrigger beams 342
6 6 13 Note on error messages with removed outrigger beams 342
7 Transport 343
7 1 Transport with transport vehicle 343
7 1 1 CHECKLIST: Checks before transport 344
7 1 2 Drive the truck crane on to the transport vehicle 346
Driving on 347
Lashing 347
7 2 Transport by ship 348
8 Malfunctions in driving mode 349
8 1 Emergency stop switch 349
8 2 Procedure during malfunctions 350
8 2 1 What to do when a malfunction occurs in road traffic 350
8 2 2 Procedure during engine malfunctions 351
8 2 3 Procedure during transmission malfunctions 352
8 3 Warning and error messages 353
8 3 1 Warning or malfunction messages on the instrument panel 353
Meaning of thelamps 353
8 3 2 Warning and malfunction messages on the on-board computer display 357
Messages 357
Symbols 358
8 3 3 Warning messages on the CCS display 361
Symbols in the display area 361
8 3 4 Error messages on the CCS display 365
Exiting the menu 366
Special error messages 366
8 4 Troubleshooting 367
8 4 1 Malfunctions on the engine 367
When operating with the dual tank 369
8 4 2 Faults on the Adblue system 369
8 4 3 Differential lock malfunctions 370
8 4 4 Transfer case malfunctions 370
8 4 5 Malfunctions in the transmission 371
8 4 6 Malfunctions of the steering 372
8 4 7 Malfunctions of the service brake 373
8 4 9 Malfunctions of the level adjustment system 374
8 4 10 Malfunctions in the hydraulic system/hydraulic oil cooler 374
8 5 Emergency operation and breakdown assistance 375
8 5 1 Starting the truck crane externally 375
8 5 2 Battery charger 376
Prerequisites 376
8 5 3 Towing the truck crane 377
In the case of engine/transmission damage 377
Longer towing distances 380
Tow starting 380
8 5 4 Wheel change 381
Removing a damaged wheel 382
On the spare wheel holder 382
Mounting a wheel 384
8 5 5 Inflating the tyres yourself 385
Connecting thefilling hose 385
Inflating the tyres 386
Remove the fillinghose 386
8 5 6 Emergency operation, steering 3rd and 4th axle lines 387
Performing emergency operation 388
After emergency operation 390
8 6 Tilting/lowering the driver’s cab 391
8 6 1 Prerequisites and information on tilting 391
8 6 2 Tilting and lowering the driver’s cab 392
Operating the hand pump 392
Tilting the driver’scab 393
Lowering the driver’s cab 394
8 7 Fuses on the carrier 397
Information on changing fuses 397
8 7 1 Fuses in the driver’s cab 398
8 7 2 Fuses in the battery box 404
Crane operation 405
9 Operating elements for crane operation 405
9 1 Overview of the operating elements 405
9 1 1 Exterior of the truck crane 406
9 1 2 Crane cab 410
Side panel 412
Crane cab, rear 414
9 1 3 Control panels 416
Left 416
Right 417
9 1 4 Control lever assignment 418
Version 1 418
Version 2 419
9 1 5 CCS control unit 420
9 1 6 Menu-independent displays 422
9 1 7 CCS – Start menu 423
RCL display 424
Display Slewing ranges/working radii 425
9 1 8 CCS – Overview menu groups 426
9 1 9 Superstructure menu group 430
Superstructure lock sub-menu 431
Counterweight menu 432
9 1 10 Menu group outrigger/driving 433
Outrigger menu 434
Outrigger cylinders menu 436
Driving menu 438
9 1 11 RCL/Telescoping menu group 441
Menu enter rigging mode/ telescope 442
Pre-selection telescoping menu 446
Lifting capacity tables menu 448
Telescoping semi- automation menu 449
Manual telescoping menu 450
9 1 12 Working range limiter menu group 451
Overall height menu 452
Working radius menu 453
Slewing angle menu 454
Hoist rope travel limitation menu 455
9 1 13 Information1 menu group 456
Hydraulic pressure and fuel consumption menu 457
9 1 14 Heating/Engine/Additional equipment menu group 458
Economy menu 459
Remote control menu 460
Heating/air- conditioning menu 461
Spotlights menu 462
9 1 15 Telescoping emergency program menu group 463
Telescoping emergency program menu 464
Unknown telescoping menu 466
9 1 16 Menu group, settings 467
Crane cab menu 468
Set display brightness and date/time menu 469
Switch units menu 470
Set control lever characteristic curve menu 471
Power unit speeds menu 472
9 1 17 Information2 menu group 473
Operating hoursmenu 474
Engine/ transmission error menu 475
Crane operation error menu 476
Program version menu 477
9 1 18 Various controls 479
9 1 19 RCL control unit 480
9 1 20 Menu-independent displays 481
9 1 21 RCL – menus 482
Monitoring menu 482
Lifting capacity tables menu 484
Datalogger menu 485
9 1 22 Hand-held control 487
9 1 23 Outriggers control units 489
Menu- independent buttons 489
Outrigger menu 490
Raise axle menu 492
9 2 Short description of the operating elements 493
9 2 1 Definition of information relating to directions of movement 493
Basic rule 493
9 2 2 General rules for buttons and symbols on the display 494
9 2 3 Engine 495
Side panel 495
Left control lever 495
Economy mode menu 496
9 2 4 AdBlue system 496
CCS display 496
9 2 5 Seat contact switch and dead man’s switch 498
9 2 6 Crane control CCS 499
9 2 7 Outrigger – crane cab 504
Control panels 504
CCS display 505
9 2 8 Outrigger control units 507
General information 507
Outrigger menu 508
9 2 9 Raise axle 510
9 2 10 Inclination indicators 512
9 2 11 Outrigger pressure displays 513
Outrigger menu 513
Outriggers controlunits 513
9 2 12 Anemometer displays 513
9 2 13 Counterweight menu 514
9 2 14 Main hoist 518
Control panels 518
CCS display 518
9 2 15 Auxiliary hoist 520
Control panels 520
CCS display 521
9 2 16 Slewing gear 522
Control panels 522
CCS display 523
9 2 17 Derricking gear 524
Control panels 524
CCS display 525
Side panel 525
9 2 18 Telescoping mechanism 526
Control panels 526
CCS display 527
Telescoping semi- automation menu 527
Manual telescoping menu 529
9 2 19 Hydraulic system 532
9 2 20 Superstructure lock/house lock menu 533
Superstructure lock 533
Houselock 535
9 2 21 Remote control 536
9 2 22 Rated capacity limiter (RCL) 537
CCS display 537
RCL display 546
RCL override – version A 547
RCL override – version B 548
9 2 23 Electrical system 549
9 2 24 Lighting, windscreen wiper/washing system 550
Lighting 550
Windscreen wiper/washing system 552
Horn 553
9 2 25 Hand-held control 554
Sockets for hand- held control 554
Engine control panel 555
Horn 555
9 2 26 Windows and doors 558
window 558
rear window 558
Crane cab door 559
9 2 27 Diagnostics 560
9 2 28 Other 560
9 3 Short description of the operating elements – driving from the crane cab 561
9 3 1 Driving menu 561
9 3 2 Transmission 563
9 3 3 Final drive 565
9 3 4 Brakes 566
CCS display 566
Side panel fromabove 566
9 3 5 Steering 567
CCS display 568
Control panels 570
10 Starting/switching off the engine – for crane operation 571
10 1 When starting the engine for the first time in the day 571
10 2 Starting the engine – from the crane cab 573
10 2 1 Check the fuel level and AdBlue level 573
Fuel 573
AdBlue 573
10 2 2 Checks before starting the engine 574
Checks on the carrier 574
Checking the hand-held control 574
At the hydraulic tank 574
10 2 3 Switching the ignition on 575
10 2 4 Comparison of switching states 576
10 2 5 Display – setting the brightness 576
10 2 6 Starting the engine 577
10 2 7 Checks after starting the engine 578
10 2 8 Setting the idling speed 579
10 3 Starting the engine – with the hand-held control 580
10 4 Switch off the engine 581
10 4 1 At the ignition lock and with hand-held control 581
After switching off 581
10 4 2 With the idling button 581
10 4 3 Using the emergency stop switches 582
Emergency stop switch, resetting 582
11 Crane operation 583
11 1 Before operating the crane 583
11 1 1 CHECKLIST: Checks before operating the crane 583
11 1 2 Check the condition of the truck crane 587
Fuel tank auxiliary heater 587
Visual inspection 587
Checking the position of the hoist ropes 588
Checking the electrical system 589
11 1 3 Adjusting the crane cab seat and front control panel 590
Crane cab seat 590
Front control panel 591
11 1 4 Checking the safety equipment 592
Rated capacity limiter 592
Lifting limit switch 592
Emergency stopswitch 593
Seat contact switch 594
11 1 5 Earthing the load 595
11 1 6 Preheating hydraulic oil 596
Prerequisites 596
Preheating 596
11 1 7 Locking/unlocking the superstructure 597
Locking points 597
Lock the superstructure 598
Unlocking the superstructure 598
11 1 8 Switching the houselock on/off 599
Switching on thehouselock 599
Switching off the houselock 601
11 2 Standard slewing range type 603
11 2 1 Permissible slewing ranges and working positions 603
360 slewing range 603
Working position 0to the rear 603
180 to the front rigging position 603
11 3 MAXbase slewing range type 605
11 3 1 Specifications in the lifting capacity tables 606
11 3 2 Enabled slewing ranges 607
11 3 3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacit 610
11 4 Operation of the rated capacity limiter 611
11 4 1 Switch on the RCL 612
Switching on 612
11 4 2 Enter rigging mode 614
Notes on Input 614
Enter the slewing range type 615
Entering individual components 616
Entering the RCLcode 622
11 4 3 Pre-selecting telescoping 622
11 4 4 Confirm the rigging mode and lifting capacity table 623
Slewing range type Standard 623
Slewing range type MAXbase 625
11 4 5 Checks before operating the crane 627
Monitoring menu 627
Checking the rigging mode 627
Hoist checking 629
11 4 6 Display during the crane operation 631
On the RCL display 631
On the CCSdisplay 635
11 4 7 RCL early warning 639
11 4 8 RCL shutdown 639
Shutdown due tooverload 639
11 4 9 Displaying the lifting capacity tables 641
Slewing range type Standard 641
Slewing range type MAXbase 643
11 4 10 RCL override – version A 645
Overview status display 645
When rigging 646
To raise the boom 647
In emergencies 648
11 4 11 RCL override – version B 649
11 4 12 Datalogger 650
Export data 650
Display the data 651
11 5 Crane operation with main boom 655
11 5 1 Checks during crane operation 655
Horizontal alignment 655
Safe distances 655
Checking the windspeed 656
11 5 2 Main hoist 657
Switching on themain hoist 658
Lifting and lowering 659
Maximum permissible hoist rope speed 660
Switching off themain hoist 660
11 5 3 Auxiliary hoist 661
Switching on the auxiliary hoist 661
Lifting and lowering 662
Maximum permissible hoist rope speed 663
Switching off the auxiliary hoist 663
11 5 4 Lifting limit switch and lowering limit switch 664
Lifting limit switch 664
Lowering limit switch 666
11 5 5 Derricking gear 667
Switching on the derricking gear 667
Raising and lowering 668
Maximum derricking speed 669
Re-enable raising function 669
Switching off the derricking gear 670
Lowering the main boom to ahorizontal position 670
11 5 6 Telescoping mechanism 671
Overview 673
Telescoping process 674
Assignment fordisplay 676
Fixed length, intermediate length, telescoping length 677
Telescoping 678
Telescoping sequence 678
Inspections prior to starting operations 679
Switching on thetelescoping mechanism 680
Function of the control lever 680
Switching off thetelescoping mechanism 682
Manual telescoping 683
Checking the initial position, 683
Unlocking the telescoping cylinder 685
Extending/retracting the telescoping cylinder 687
Lock telescoping cylinder 688
Unlocking the telescopic section 689
Telescoping the telescopic section 690
Locking the telescopic section 691
Locking the telescopic section for on-road driving 692
Telescoping with semi-automaton 692
Telescoping with pre-selection 694
11 5 7 High-speed mode 695
Derricking gear Telescoping mechanism 695
Hoists 695
11 5 8 Slewing gear 697
Slewing gear brake 697
Switching on the slewing gear 698
Releasing the slewing gear brake 698
Applying the slewing gear brake 698
Slewing 699
Permissible slewing speed 700
Braking the slewing movement 701
Slewing gear freewheel 701
Switching off the slewing gear 702
11 5 9 Switching the reduction of slewing speed on and off 703
Switching reduction off 703
11 5 10 Possible movement combinations 704
11 6 Settings and displays for crane operation 705
11 6 1 Inclining the crane cab 705
11 6 2 Idling speed, setting 706
11 6 3 Adjusting the wiper stroke interval of the windscreen wiper 706
11 6 4 Limiting the power unit speeds 707
11 6 5 Economy mode 708
Switching on 708
Ending/ switchingoff 710
11 6 6 Switching units of measure 710
11 6 7 Setting the characteristic curves for the control levers 711
11 6 8 Using the slewable spotlights 712
Manually swinging 713
Automatic load tracking 713
11 6 9 Overriding torque reduction 714
11 6 10 Displaying the operating hours 715
11 7 Working range limiter 717
11 7 1 viewing current settings 718
On the RCL dislay 718
In the CCS Startmenu 719
11 7 2 Opening the working range limiter menu 719
11 7 3 Enter limit values – for the overall height 720
11 7 4 Enter limit values – for the working radius 722
11 7 5 Enter limit values – for the slewing range 724
11 7 6 Enter limit values – for the hoist rope travel 727
11 7 7 Shutdown by working range limiter 729
11 8 Work break 731
11 8 1 In case of short work breaks 731
11 8 2 In case of work breaks of more than 8 hours 732
To secure the truck crane 732
11 9 Heating and air-conditioning system 733
11 9 1 Standard heating system 733
Switching on 733
Heating 733
Air distribution 734
Switching off 734
11 9 2 Air-conditioning system 735
Notes 735
Switching on/off 735
Cooling, automatic 736
Cooling, maximum 736
11 9 3 Auxiliary heater 737
Switching on 737
Setting the temperature 738
Setting the heating start/ heating duration 738
Switching heating start on/off 739
11 10 CraneSTAR system 740
11 10 1 Overview 740
11 10 2 Position of the components 740
12 Rigging work 741
12 1 Rigging work checklists for crane operation with themain boom 741
12 1 1 CHECKLIST: Rigging 741
12 1 2 CHECKLIST: Unrigging 747
12 2 Choice of a suitable positioning site 751
12 2 1 Determining the required load-bearing area 751
12 2 2 Safe distance from slopes and pits 754
12 2 3 Earthing the truck crane 755
12 2 4 Safe distance from overhead power lines 756
12 3 Rigging work after driving with a dolly 759
12 3 1 Switching off the boom floating position 759
12 3 2 Switching off the slewing gear freewheel 760
Before slewing 760
12 3 3 Switching off boom pre-tensioning 761
12 4 Connecting/disconnecting the hand-held control 763
12 5 Starting the engine for rigging 767
12 5 1 Starting/shutoff the engine – with the hand-held control 767
Prerequisites 767
Starting theengine 768
Turning off theengine 768
12 5 2 Starting/shutoff the engine – from the outrigger control units 769
Prerequisites 769
Starting theengine 769
Switch off theengine 769
12 6 Slewing range – only with the Standard slewing range type 771
12 6 1 Representation in the lifting capacity tables 771
12 6 2 Enabled outrigger spans 772
12 7 Outriggers – Overview – MAXbase slewing range type 773
12 7 1 Definitions 773
12 7 2 Representation in the lifting capacity tables 775
12 7 3 Enabled outrigger spans 776
12 8 Outrigger operation 781
12 8 1 CHECKLIST: Extending the outriggers 781
12 8 2 CHECKLIST: Retracting the outriggers 783
12 8 3 Preparing the truck crane 784
Driver’s cab 784
Crane cab 784
12 8 4 Setting the outrigger spans 786
For on-road driving 789
12 8 5 Extending/retracting outrigger beams 789
From the cranecab 790
From the controlunits 791
12 8 6 Moving the outrigger pads into operating/driving position 793
12 8 7 Enlarging the load-bearing area 795
12 8 8 Extending/retracting supporting cylinders 796
From the controlunits 797
From the cranecab 798
12 8 9 Levelling the truck crane on outriggers horizontally 800
Inclination indicators 800
Prerequisites 801
Manual alignment 802
Automatic alignment 802
12 8 10 Levelling the free-standing truck crane 804
12 8 11 Operating the axle raising system 806
12 8 12 Outrigger pressure display 808
12 9 Rigging/unrigging the counterweight 811
12 9 1 Information on rigging 811
When rigging 811
When unrigging 812
12 9 2 Counterweight sections 813
Version 1 813
Version 2 813
Version 3 814
12 9 3 Identification 815
12 9 4 Slinging points on the counterweight sections 816
12 9 5 CHECKLIST: Rigging the counterweight 817
12 9 6 CHECKLIST: Unrigging the counterweight 819
12 9 7 Assembling counterweight combination 820
Setting down the2 3 t base plate 821
Setting down the top couterweight section 821
Version 1 822
Version 2 830
Version 3 834
12 9 8 Counterweight hoist unit 842
Counterweight menu 842
Extending/retracting the lifting cylinders 843
Automatic mode rigging 845
Automatic mode unrigging 847
Cancel automatic mode 848
12 9 9 Removing/installing the counterweight on the turntable 849
Removing 849
Installing 850
12 9 10 Setting down counterweight for driving 851
Versions 1 and 3 851
Version 2 853
12 9 11 Slewing with rigged counterweight 853
12 10 Rigging work on the main boom 855
12 10 1 Hook block on the bumper 855
Picking up the hook block 855
Attaching the hook block 856
12 10 2 Hook block on a separate vehicle 857
Picking up the hook block 858
Setting down thehook block 858
12 10 3 Hook block, separable 860
Rigging for on- road driving 860
Rigging for crane operation 861
12 10 4 Hook block with ballast plates 862
Removing 862
Installing 863
Information on crane operation 863
12 10 5 Reeving and unreeving the hoist rope 864
Version A 864
Version B 865
Reeving the hoistrope 867
Unreeving hoistrope 871
12 10 6 Possible reevings on the main boom 872
With 6 head sheaves 872
With 8 head sheaves 875
With 9 head sheaves 878
12 10 7 Installing/removing the lifting limit switch 879
Installing the lifting limit switch 879
Removing the lifting limit switch 882
12 10 8 Locking/unlocking the lifting limit switch 884
Locking 884
Removing the lock 884
12 10 9 Anemometer and air traffic control light 885
Installing 885
Switching on/off 886
Removing 887
12 11 Other rigging work 889
12 11 1 Railings on the turntable 889
12 11 2 Folding the mirrors in and out, and adjusting them 890
12 11 3 Slinging points for personal protective equipment 891
12 11 4 Cameras for crane operation 892
Camera on mainboom 892
Camera on thehoists 895
Camera on the driver’s cab 895
Operating thecamera 896
12 11 5 Step at the crane cab 897
13 Driving with a rigged truck crane 899
13 1 Route 899
13 2 Permissible rigging modes and axle loads 900
Axle load table 900
13 2 1 To drive without a load 903
13 2 2 To drive with a load 903
13 2 3 Axle loads 904
13 3 Before driving the rigged truck crane 905
13 3 1 Check the tyre pressures and wind speed 905
13 3 2 Secure the superstructure against slewing 905
13 3 3 Putting the truck crane on the wheels – with Raise axle function 906
13 3 4 Putting the truck crane on the wheels – with the outriggers 908
13 4 Driving from the driver’s cab 911
13 4 1 Preparing to drive 911
Transmission 911
Switching on separate steering 911
Connections 911
13 4 2 Whilst driving 912
13 4 3 After driving 913
13 5 Driving from the crane cab 915
13 5 1 Preparing to drive 916
13 5 2 Opening/closing the driving menu 917
Opening the menu 917
Selecting the operating mode 917
Crane’s hydraulic system Driving mode 919
Closing menu 919
13 5 3 Steering 920
Switching on 920
Display and steering direction 920
Switching the steering direction 921
Displays whensteering 921
Separate steering 922
Normal steering mode 925
13 5 4 Operating the transmission 926
Selecting the transmission mode 926
13 5 5 Whilst driving 927
DMand RM transmission mode 927
Transmission mode D 927
Warning messages 927
13 5 6 Possible connections 928
Longitudinal/ transverse differential locks 928
13 5 7 After driving 930
14 Malfunctions during crane operation 931
14 1 Emergency stop switch 931
14 2 What to do when malfunctions occur during crane operation 932
The load can be set down 932
Load cannot besetdown 932
14 3 Warning and error messages 933
Program version 933
14 3 1 Warning messages on the CCS display 933
Meaning of the symbols 934
14 3 2 Error messages on the CCS display 938
14 3 3 Warning messages on the RCL display 940
14 4 Troubleshooting 945
14 4 1 Malfunctions on the engine 945
14 4 2 Malfunctions on the main hoist/auxiliary hoist 945
14 4 3 Malfunctions in the hoist cameras 947
14 4 4 Malfunctions in the main boom camera 947
14 4 5 Malfunctions on the derricking gear 948
14 4 6 Malfunctions in the telescoping mechanism 949
14 4 7 Malfunctions on the slewing gear 950
14 4 8 Malfunctions on the counterweight hoist unit 952
14 4 9 Malfunctions in the hydraulic system/hydraulic oil cooler 952
14 4 10 Malfunctions when operating with the hand-held control 953
14 4 11 Malfunctions when inclining the crane cab 953
14 4 12 Malfunctions when raising the axles 953
14 4 13 Malfunctions of the outriggers 954
14 4 14 Malfunctions on the turntable lock 954
14 4 15 Malfunctions on the CCS/RCL control units 955
14 4 16 Malfunctions when driving from the crane cab 955
14 4 17 Malfunctions on the CraneSTAR system 956
14 5 Emergency operations and programs 959
14 5 1 Mechanical emergency activation for retracting 960
Prior to the emergency operation, check 960
Procedure 960
Mechanical emergency activation 961
14 5 2 Telescoping emergency program 963
Telescoping emergency program menu 963
Determining the type of error 964
Error at the lengthindicator 965
Tables for approaching the locking points 969
14 5 3 Entering the current telescoping 971
14 5 4 Emergency operation with the hand-held control 973
To pre-select a power unit 974
Operating apowerunit 974
Stopping movements 975
Stopping movements in emergencies 976
Switch off theengine 976
14 5 5 Notes on slewing in emergency operation 976
For the Standard slewing range type 976
For the MAXbase slewing range type 978
14 5 6 Rotate for overridden slewing gear shutdown 979
14 6 Hydraulic emergency operation with the hand pump 981
14 6 2 Switching over the crane’s hydraulic system 982
14 6 3 Establishing the hydraulic circuits required 983
Releasing/ securing valves 983
Switching overvalves 984
For lowering 985
14 6 4 Performing emergency activation 986
14 6 5 After emergency activation 987
14 7 Hydraulic emergency operation acc to BGR159 989
14 7 1 Applications and function 989
14 7 2 CHECKLIST: Emergency operation 991
14 7 3 CHECKLIST: After emergency operation 992
14 7 4 Connecting/removing transformer – for self-sufficiency 993
Connecting 993
Removing 994
14 7 5 Switching emergency operation on/off 995
14 7 6 Connecting/removing transformer – for external energy source 996
14 7 7 Establishing the required hydraulic circuits 997
Valves at the control panel 997
For lifting/ lowering 999
For slewing 1000
14 7 8 Performing emergency operation 1001
Slewing 1001
Derricking 1002
Lifting/lowering 1002
14 7 9 Emergency supply of another crane 1003
For emergency supply 1003
After emergency supply 1003
14 8 Fuses in the crane cab 1005
Information on changing fuses 1005
Index 1011
A 1013
B 1013
C 1014
D 1016
E 1018
F 1020
H 1020
I 1021
L 1021
M 1022
O 1023
P 1025
R 1025
S 1026
T 1027
V 1029
W 1029

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S.M