Manitowoc Grove Crane GMK5150L Operating Manual PDF

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Manitowoc Grove Crane GMK5150L Operating Manual 3302709 – PDF DOWNLOAD

The Manitowoc Grove GMK5150L Operating Manual (3302709) is a vital 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 :1034
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
Telescoping emergency programme 7
Return run of the telescoping cylinder 7
Table of contents 11
General 41
1 Overview 41
1 1 Accidents 41
1 2 Branch offices 43
1 2 1 Manitowoc Crane Care 43
1 2 2 Dealer list 43
1 3 Warranty specifications 43
1 4 Terms used 44
1 5 Technical data 47
1 5 1 Maximum lifting capacity (ASME B 30 5) 47
1 5 2 Dimensions and weights of the truck crane, axle loads 48
Dimensions 49
Weight and axleloads 49
1 5 3 Dimensions and weights of removable parts 50
Spare wheel 50
Outrigger 50
Main boom 50
Hook blocks andhook tackle 51
Auxiliary hoist 53
Counterweight parts 54
1 5 4 Carrier 57
Engine 57
Transmission 57
Transfer case 57
Axle lines 57
Steering 58
Tyres 58
Turning turningradii 58
Outrigger 59
Electrical system 60
Tool 60
Towing couplings 60
Driving speeds 60
Climbing ability 60
1 5 5 Superstructure 61
Main hoist 61
Auxiliary hoist 61
Slewing gears 61
Derricking gear 61
Main boom 62
Lattice extension 62
Operating speeds 62
1 6 Documentation supplied 63
1 6 1 Questions on documentation 64
1 7 Notes on the operating manual 65
1 7 1 What do the symbols used mean? 65
1 7 2 How is the operating manual structured? 67
Division 67
Structure of the chapters 67
Structure of thepages 68
1 7 3 How do I find the information I need? 69
Cross-references example 70
1 7 4 What information is available for operations planning? 72
1 8 Conversion table for US measuring units 73
1 9 Training – Information 75
1 10 Identification 76
1 11 EC Declaration of Conformity 78
2 Basic safety instructions 79
2 1 Intended use 79
2 1 1 Improper use 80
2 2 Organisational measures 81
2 3 Personnel qualifications 83
2 4 Safety instructions for driving the truck crane 84
2 5 Safety instructions for crane operation 85
2 6 Instructions on transporting persons 88
Equipment for lifting persons 88
Personnel 88
Operation 89
Truck crane 90
Driving 91
3 Operating elements for driving 91
3 1 Overview of the operating elements 91
3 1 1 On the outside of the truck crane 92
3 1 2 Driver’s cab 96
Front overview 96
Rear overview 98
Behind the cover 99
3 1 3 Steering column/steering wheel 100
3 1 4 Instrument panel 101
Left/right 101
Middle 102
3 1 5 Transmission operating elements 104
3 1 6 On-board computer 105
3 1 7 Tachograph 106
3 1 8 Heating and air-conditioning system 107
Standard 107
Auxiliary water heating system 108
Auxiliary air heater 109
3 1 9 CCS control unit 111
3 1 10 CCS – menu-dependent displays 112
3 1 11 CCS – Start menu 113
3 1 12 CCS – Overview menu groups 114
3 1 13 Carrier menu group 116
Suspension/level adjustment menu 117
Driving menu 118
3 1 14 Settings menu group 119
Set display brightness and date/time menu 120
Switch units menu 121
3 1 15 Menu group Information 122
Operating hoursmenu 123
Engine/transmission error menu 124
Crane operation error menu 125
3 1 16 Various controls menu group 126
3 1 17 Emergency operations menu group 127
3 1 18 Outrigger control units 128
3 2 Short description of the operating elements 129
3 2 1 Definition of information relating to directions of movement 130
Basic rule 130
3 2 2 General rules for buttons and symbols on the display 131
3 2 3 Engine 132
Steering column 132
On the steering wheel 132
Instrument panel 133
3 2 4 AdBlue system 134
Instrument panel 134
CCS display 135
3 2 5 Battery master switch 135
3 2 6 Electrical system 136
3 2 7 Crane control CCS 137
3 2 8 Transmission 139
Transmission control unit 139
Display, drivingmode 141
3 2 9 Reverse camera 142
3 2 10 BirdView system 270 143
3 2 11 Transfer case 145
3 2 12 Final drive 147
3 2 13 Brakes 148
Service brake 148
Additional brakes 148
Parking brake 149
3 2 14 Steering/separate steering 150
Instrument panel 150
CCS display 152
3 2 15 Suspension 154
CCS display 154
3 2 16 Lighting/windscreen wipers/horn 155
Steering column 155
Steering wheel 155
Instrument panel 155
CCS display 157
Roof 157
3 2 17 Level adjustment system 158
3 2 18 Tachograph/speedometer 160
Tachograph 160
Cover 160
Speedometer 160
3 2 19 Diagnostics 161
3 2 20 Push-up roof 161
3 2 21 On-board computer 162
3 2 22 Front flap 163
3 2 23 Windows and doors 164
Window winder 164
Doors 165
3 2 24 Access ladders and ladders 167
4 Starting the engine for driving / switching it off 171
4 1 Starting the engine from the driver’s cab 171
4 1 1 CHECKLIST: Starting the engine 171
4 1 2 CHECKLIST: At low temperatures 174
4 1 3 Filling up 175
Fuel tank 175
AdBlue tank 177
4 1 4 Checks before starting the engine 178
At the hydraulictank 178
Battery master switch 179
Checking the hand-held control 179
4 1 5 Switch the ignition on 179
4 1 6 Lamp test/equalisation of the switching states 180
Lamp test 180
Switching state alignment 180
4 1 7 Display – setting the brightness 181
4 1 8 Starting the engine 183
4 1 9 Checks after starting the engine 185
Start menu andon-board computer 185
Instrument panel 186
4 1 10 Setting the idling speed 187
4 2 Switch off the engine 188
4 2 1 At the ignition lock and with the outrigger control units 188
After switching off 188
4 2 2 Using the emergency stop switches 189
Resetting the emergency stopswitch 189
4 3 Air intake inhibitor 190
Opening the air intake inhibitor 190
5 Driving 191
5 1 Before driving 191
5 1 1 CHECKLIST: checks before on-road driving 191
5 1 2 Check the condition of the truck crane 197
Electrical system 197
Adjusting themirrors 197
Warning plates for vehicle width 199
Checking the vehicle height 199
Supply pressure 200
Parking brake 201
Third brake light 202
5 1 3 Adjusting the seat and the steering column 203
Adjusting the driver’s seat 203
Adjusting the passenger seat 204
Adjusting the steering column 205
5 1 4 Switching the suspension on/off 206
Open menu 206
Switching the suspension on 207
Switching the suspension off 207
5 1 5 Setting the tachograph 208
Prerequisites 208
In the event of malfunctions 208
Setting the tachograph 209
5 1 6 Setting the time 213
5 1 7 Displaying and resetting operating hours 214
5 2 Operating the transmission 215
5 2 1 Switching on 215
5 2 2 Switching the transmission to the neutral position 216
5 2 3 Selecting the direction of travel and starting gear 217
Selecting the driving direction 217
Selecting the starting gear  218
5 2 4 Changing the operating mode 219
Changing to automatic mode 219
Change to manualmode 219
5 2 5 Starting 220
5 2 6 Driving and changing gears 221
In automatic operating mode 221
In manual operating mode 222
5 2 7 Changing the driving direction 223
5 2 8 Stopping 223
Stopping for longer periods 223
5 2 9 On the roller type dynamometer 224
5 2 10 Preheating transmission 224
5 3 Driving the truck crane and switching it off 225
5 3 1 Checks whilst driving 225
Brakes 225
ABS system 225
Steering 226
Warning messages 226
Monitoring elements 227
5 3 2 Cruise control 228
Switching on 228
Switching off 229
5 3 3 Temposet 230
Switching on 230
Switching off 230
5 3 4 Driving downhill 231
Starting 231
Checks when driving downhill 232
Downshifting 232
Additional brakes 233
5 3 5 Driving uphill 234
Starting 234
Driving 234
5 3 6 Overriding torque reduction 235
5 3 7 Switching the truck crane off 236
Secure it against rolling away 236
When stationary for more than 8hours 237
5 3 8 Fold-up berth 238
5 4 Off-road driving 239
Adjustments to the transmission 239
Connections 239
Changing the vehicle level 239
Rocking the vehicle free and towing 239
5 4 1 Transfer case – switching the off-road gear on/off 240
5 4 2 Longitudinal and transverse differential locks 241
5 4 3 Operating the level adjustment system 243
Open menu 243
Setting the on-road level 244
Pre-selecting suspension struts 244
Changing the vehicle level 245
Viewing the current inclination 246
Exiting the menu 246
5 4 4 Freeing truck crane stuck in terrain 247
Rocking the truck crane free 247
Towing free forwards 248
Towing free totherear 248
5 5 Separate steering 249
5 5 1 Switching to separate steering 250
5 5 2 Switching to normal steering mode 253
5 5 3 Switching units of measure 254
5 6 Heating and air-conditioning system 255
5 6 1 Standard heating system 255
Switching on 255
Heating 255
Air distribution 256
Examples 257
Switching off 257
5 6 2 Air-conditioning system 258
Notes 258
Switching on/off 258
Cooling 259
Drying 259
5 6 3 Auxiliary water heating system 260
Preheating theengine 260
Preheating the driver’s cab 261
Switching on 261
Setting the date and time 263
Storing the heating start 264
5 6 4 Auxiliary air heater 266
Switching on 266
Setting the heating level 267
Setting the day and time 268
Setting the preselection time 268
Preselection timesDelete 270
Switching off 270
5 7 Radio 270
5 8 Towing a trailer 271
Effects on the axleloads 271
Coupling thetrailer 272
Connecting the supply lines 273
Removing supplylines 274
Uncoupling thetrailer 274
Checking the braking force 276
6 Driving modes and rigging for on-road driving 277
6 1 Driving modes 277
Information about the axle loads 277
6 1 1 How to use the tables 278
6 1 2 Table for a maximum axle load of 12 t (26,500 lbs) 279
Tyres 385/95 R25 279
Tyres 445/95 R25 280
Tyres 525/80 R25 281
6 1 3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs) 282
6 2 Weighing the truck crane 283
Axle groups 284
Weighing procedure 285
Evaluation 286
6 3 Rigging work for driving with a dolly 287
6 3 1 Switching on the slewing gear freewheel 288
6 3 2 Switching on the boom floating position 289
6 3 3 Switching on boom pre-tensioning 290
6 3 4 Raising/lowering the 3rd axle line for dolly operation 291
6 4 Rigging the main boom 293
Additional equipment required 293
6 4 1 CHECKLIST: Removing the main boom 294
Prerequisites 294
Checklist 294
6 4 2 CHECKLIST: Mounting the main boom 297
Prerequisites 297
Checklist 297
6 4 3 Disconnecting/connecting hydraulics/electrical 300
6 4 4 Derricking cylinder support 302
6 4 5 Slinging the main boom 302
Marking 302
Attach lifting gear 303
Removing the sling gear 304
6 4 6 Switching the pressure relief on/off 305
6 4 7 Retracting/fitting the derricking cylinder head pin 306
Operating the lifting device 306
Pulling the derricking cylinder head axle 306
Fitting the derricking cylinder head axle 307
6 4 8 Extending/retracting the boom pivot pin 308
Pulling out the pivot pin 308
Pushing the pivotpin in 310
6 4 9 Transporting the main boom 311
6 4 10 Securing/releasing the derricking cylinder 311
6 4 11 Aligning the connecting points 312
6 4 12 Inspections after main boom mounting 313
6 5 Rigging the auxiliary hoist 315
6 5 1 Slinging the auxiliary hoist 315
6 5 2 CHECKLIST: Installing the auxiliary hoist 316
6 5 3 CHECKLIST: Removing the auxiliary hoist 317
6 5 4 Making/breaking the connection between the auxiliary hoist and the turntable 318
6 5 5 Establishing/disconnecting the hydraulic connections 319
6 5 6 Disconnecting/establishing the electrical connection 320
6 5 7 Making/breaking the connection to the central lubrication 321
6 5 8 Transporting the auxiliary hoist 322
6 5 9 Check that the auxiliary hoist is functioning properly 323
Slewing direction 323
Slewing indicator 323
6 5 10 Rigging aid for the hoist rope 324
6 6 Installing/removing the outrigger beams 327
6 6 1 CHECKLIST: Removing the outrigger beams 328
6 6 2 CHECKLIST: Installing the outrigger beams 330
6 6 3 Centre of gravity data 332
6 6 4 Preparations – for removal 332
6 6 5 Preparations – on the truck crane 333
Prerequisites 333
6 6 6 Removing/attaching outrigger pads 334
Removing the outrigger pads 334
Attaching the outrigger pads 335
6 6 7 Disconnecting/establishing hydraulic connection 336
6 6 8 Disconnecting/establishing the electrical connection 337
6 6 9 Unscrewing/screwing in the spacers 338
Unscrewing 338
Screwing in 339
6 6 10 Disconnecting/establishing the connections to the supporting box 340
6 6 11 Pulling out/Inserting the outrigger beam 340
Extending the outrigger beam 340
Inserting the outrigger beam 342
6 6 12 Transporting the outrigger beams 344
6 6 13 Note on error messages with removed outrigger beams 344
7 Transport 345
7 1 Transport with transport vehicle 345
7 1 1 CHECKLIST: Checks before transport 346
7 1 2 Drive the truck crane on to the transport vehicle 348
Driving on 349
Lashing 349
7 2 Transport by ship 350
8 Malfunctions in driving mode 351
8 1 Emergency stop switch 351
8 2 Procedure during malfunctions 352
8 2 1 What to do when a malfunction occurs in road traffic 352
8 2 2 Procedure during engine malfunctions 353
8 2 3 Procedure during transmission malfunctions 354
8 3 Warning and error messages 355
8 3 1 Warning or malfunction messages on the instrument panel 355
Meaning of thelamps 355
8 3 2 Warning and malfunction messages on the on-board computer display 359
Messages 359
Symbols 360
8 3 3 Warning messages on the CCS display 363
Symbols in the display area 363
8 3 4 Error messages on the CCS display 367
Exiting the menu 368
Special error messages 368
8 4 Troubleshooting 369
8 4 1 Malfunctions on the engine 369
When operating with the dual tank 371
8 4 2 Faults on the Adblue system 371
8 4 3 Differential lock malfunctions 372
8 4 4 Transfer case malfunctions 372
8 4 5 Malfunctions in the transmission 373
8 4 6 Malfunctions of the steering 374
8 4 7 Malfunctions of the service brake 375
8 4 9 Malfunctions of the level adjustment system 376
8 4 10 Malfunctions in the hydraulic system/hydraulic oil cooler 376
8 5 Emergency operation and breakdown assistance 377
8 5 1 Starting the truck crane externally 377
8 5 2 Battery charger 378
Prerequisites 378
8 5 3 Towing the truck crane 379
In the case of engine/transmission damage 379
Longer towing distances 382
Tow starting 382
8 5 4 Wheel change 383
Removing a damaged wheel 384
On the spare wheel holder 384
Mounting a wheel 386
8 5 5 Inflating the tyres yourself 387
Connecting thefilling hose 387
Inflating the tyres 388
Remove the fillinghose 388
8 5 6 Emergency operation, steering 3rd and 4th axle lines 389
Performing emergency operation 390
After emergency operation 392
8 6 Tilting/lowering the driver’s cab 393
8 6 1 Prerequisites and information on tilting 393
8 6 2 Tilting and lowering the driver’s cab 394
Operating the hand pump 394
Tilting the driver’scab 395
Lowering the driver’s cab 396
8 7 Fuses on the carrier 399
Information on changing fuses 399
8 7 1 Fuses in the driver’s cab 400
8 7 2 Fuses in the battery box 406
Crane operation 407
9 Operating elements for crane operation 407
9 1 Overview of the operating elements 407
9 1 1 Exterior of the truck crane 408
9 1 2 Crane cab 412
Side panel 414
Crane cab, rear 416
9 1 3 Control panels 418
Left 418
Right 419
9 1 4 Control lever assignment 420
Version 1 420
Version 2 421
9 1 5 CCS control unit 422
9 1 6 Menu-independent displays 424
9 1 7 CCS – Start menu 425
RCL display 426
Display Slewing ranges/working radii 427
9 1 8 CCS – Overview menu groups 428
9 1 9 Superstructure menu group 432
Superstructure lock sub-menu 433
Counterweight menu 434
9 1 10 Menu group outrigger/driving 435
Outrigger menu 436
Outrigger cylinders menu 438
Driving menu 440
9 1 11 RCL/Telescoping menu group 443
Menu enter rigging mode/ telescope 444
Pre-selection telescoping menu 448
Lifting capacity tables menu 450
Telescoping semi- automation menu 451
Manual telescoping menu 452
9 1 12 Working range limiter menu group 453
Overall height menu 454
Working radius menu 455
Slewing angle menu 456
Hoist rope travel limitation menu 457
9 1 13 Information1 menu group 458
Hydraulic pressure and fuel consumption menu 459
9 1 14 Heating/Engine/Additional equipment menu group 460
Economy menu 461
Remote control menu 462
Heating/air- conditioning menu 463
Spotlights menu 464
9 1 15 Telescoping emergency program menu group 465
Telescoping emergency program menu 466
Unknown telescoping menu 468
9 1 16 Menu group, settings 469
Crane cab menu 470
Set display brightness and date/time menu 471
Switch units menu 472
Set control lever characteristic curve menu 473
Power unit speeds menu 474
9 1 17 Information2 menu group 475
Operating hoursmenu 476
Engine/ transmission error menu 477
Crane operation error menu 478
Program version menu 479
9 1 18 Various controls 481
9 1 19 RCL control unit 482
9 1 20 Menu-independent displays 483
9 1 21 RCL – menus 484
Monitoring menu 484
Lifting capacity tables menu 486
Datalogger menu 487
9 1 22 Hand-held control 489
9 1 23 Outriggers control units 491
Menu- independent buttons 491
Outrigger menu 492
Raise axle menu 494
9 2 Short description of the operating elements 495
9 2 1 Definition of information relating to directions of movement 495
Basic rule 495
9 2 2 General rules for buttons and symbols on the display 496
9 2 3 Engine 497
Side panel 497
Left control lever 497
Economy mode menu 498
9 2 4 AdBlue system 498
CCS display 498
9 2 5 Seat contact switch and dead man’s switch 500
9 2 6 Crane control CCS 501
9 2 7 Outrigger – crane cab 506
Control panels 506
CCS display 507
9 2 8 Outrigger control units 509
General information 509
Outrigger menu 510
9 2 9 Raise axle 512
9 2 10 Inclination indicators 514
9 2 11 Outrigger pressure displays 515
Outrigger menu 515
Outriggers controlunits 515
9 2 12 Anemometer displays 515
9 2 13 Counterweight menu 516
9 2 14 Main hoist 520
Control panels 520
CCS display 520
9 2 15 Auxiliary hoist 522
Control panels 522
CCS display 523
9 2 16 Slewing gear 524
Control panels 524
CCS display 525
9 2 17 Derricking gear 526
Control panels 526
CCS display 527
Side panel 527
9 2 18 Telescoping mechanism 528
Control panels 528
CCS display 529
Telescoping semi- automation menu 529
Manual telescoping menu 531
9 2 19 Hydraulic system 534
9 2 20 Superstructure lock/house lock menu 535
Superstructure lock 535
Houselock 537
9 2 21 Remote control 538
9 2 22 Rated capacity limiter (RCL) 539
CCS display 539
RCL display 548
RCL override – version A 549
RCL override – version B 550
9 2 23 Electrical system 551
9 2 24 Lighting, windscreen wiper/washing system 552
Lighting 552
Windscreen wiper/washing system 554
Horn 555
9 2 25 Hand-held control 556
Sockets for hand- held control 556
Engine control panel 557
Horn 557
9 2 26 Windows and doors 560
window 560
rear window 560
Crane cab door 561
9 2 27 Diagnostics 562
9 2 28 Other 562
9 3 Short description of the operating elements – driving from the crane cab 563
9 3 1 Driving menu 563
9 3 2 Transmission 565
9 3 3 Final drive 567
9 3 4 Brakes 568
CCS display 568
Side panel fromabove 568
9 3 5 Steering 569
CCS display 570
Control panels 572
10 Starting/switching off the engine – for crane operation 573
10 1 When starting the engine for the first time in the day 573
10 2 Starting the engine – from the crane cab 575
10 2 1 Check the fuel level and AdBlue level 575
Fuel 575
AdBlue 575
10 2 2 Checks before starting the engine 576
Checks on the carrier 576
Checking the hand-held control 576
At the hydraulic tank 576
10 2 3 Switching the ignition on 577
10 2 4 Comparison of switching states 578
10 2 5 Display – setting the brightness 578
10 2 6 Starting the engine 579
10 2 7 Checks after starting the engine 580
10 2 8 Setting the idling speed 581
10 3 Starting the engine – with the hand-held control 582
10 4 Switch off the engine 583
10 4 1 At the ignition lock and with hand-held control 583
After switching off 583
10 4 2 With the idling button 583
10 4 3 Using the emergency stop switches 584
Emergency stop switch, resetting 584
11 Crane operation 585
11 1 Before operating the crane 585
11 1 1 CHECKLIST: Checks before operating the crane 585
11 1 2 Check the condition of the truck crane 589
Fuel tank auxiliary heater 589
Visual inspection 589
Checking the position of the hoist ropes 590
Checking the electrical system 591
11 1 3 Adjusting the crane cab seat and front control panel 592
Crane cab seat 592
Front control panel 593
11 1 4 Checking the safety equipment 594
Rated capacity limiter 594
Lifting limit switch 594
Emergency stopswitch 595
Seat contact switch 596
11 1 5 Earthing the load 597
11 1 6 Preheating hydraulic oil 598
Prerequisites 598
Preheating 598
11 1 7 Locking/unlocking the superstructure 599
Locking points 599
Lock the superstructure 600
Unlocking the superstructure 600
11 1 8 Switching the houselock on/off 601
Switching on thehouselock 601
Switching off the houselock 603
11 2 Standard slewing range type 605
11 2 1 Permissible slewing ranges and working positions 605
360 slewing range 605
Working position 0to the rear 605
180 to the front rigging position 605
11 3 MAXbase slewing range type 607
11 3 1 Specifications in the lifting capacity tables 608
11 3 2 Enabled slewing ranges 609
11 3 3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacit 612
11 4 Operation of the rated capacity limiter 613
11 4 1 Switch on the RCL 614
Switching on 614
11 4 2 Enter rigging mode 616
Notes on Input 616
Enter the slewing range type 617
Entering individual components 618
Entering the RCLcode 624
11 4 3 Pre-selecting telescoping 624
11 4 4 Confirm the rigging mode and lifting capacity table 625
Slewing range type Standard 625
Slewing range type MAXbase 627
11 4 5 Checks before operating the crane 629
Monitoring menu 629
Checking the rigging mode 629
Hoist checking 631
11 4 6 Display during the crane operation 633
On the RCL display 633
On the CCSdisplay 637
11 4 7 RCL early warning 641
11 4 8 RCL shutdown 641
Shutdown due tooverload 641
11 4 9 Displaying the lifting capacity tables 643
Slewing range type Standard 643
Slewing range type MAXbase 645
11 4 10 RCL override – version A 647
Overview status display 647
When rigging 648
To raise the boom 649
In emergencies 650
11 4 11 RCL override – version B 651
11 4 12 Datalogger 652
Export data 652
Display the data 653
11 5 Crane operation with main boom 657
11 5 1 Checks during crane operation 657
Horizontal alignment 657
Safe distances 657
Checking the windspeed 658
11 5 2 Main hoist 659
Switching on themain hoist 660
Lifting and lowering 661
Maximum permissible hoist rope speed 662
Switching off themain hoist 662
11 5 3 Auxiliary hoist 663
Switching on the auxiliary hoist 663
Lifting and lowering 664
Maximum permissible hoist rope speed 665
Switching off the auxiliary hoist 665
11 5 4 Lifting limit switch and lowering limit switch 666
Lifting limit switch 666
Lowering limit switch 668
11 5 5 Derricking gear 669
Switching on the derricking gear 669
Raising and lowering 670
Maximum derricking speed 671
Re-enable raising function 671
Switching off the derricking gear 672
Lowering the main boom to ahorizontal position 672
11 5 6 Telescoping mechanism 673
Overview 675
Telescoping process 676
Assignment fordisplay 678
Fixed length, intermediate length, telescoping length 679
Telescoping 680
Telescoping sequence 680
Inspections prior to starting operations 681
Switching on thetelescoping mechanism 682
Function of the control lever 682
Switching off thetelescoping mechanism 684
Manual telescoping 685
Checking the initial position, 685
Unlocking the telescoping cylinder 687
Extending/retracting the telescoping cylinder 689
Lock telescoping cylinder 690
Unlocking the telescopic section 691
Telescoping the telescopic section 692
Locking the telescopic section 693
Locking the telescopic section for on-road driving 694
Telescoping with semi-automaton 694
Telescoping with pre-selection 696
11 5 7 High-speed mode 697
Derricking gear Telescoping mechanism 697
Hoists 697
11 5 8 Slewing gear 699
Slewing gear brake 699
Switching on the slewing gear 700
Releasing the slewing gear brake 700
Applying the slewing gear brake 700
Slewing 701
Permissible slewing speed 702
Braking the slewing movement 703
Slewing gear freewheel 703
Switching off the slewing gear 704
11 5 9 Switching the reduction of slewing speed on and off 705
Switching reduction off 705
11 5 10 Possible movement combinations 706
11 6 Settings and displays for crane operation 707
11 6 1 Inclining the crane cab 707
11 6 2 Idling speed, setting 708
11 6 3 Adjusting the wiper stroke interval of the windscreen wiper 708
11 6 4 Limiting the power unit speeds 709
11 6 5 Economy mode 710
Switching on 710
Ending/ switchingoff 712
11 6 6 Switching units of measure 712
11 6 7 Setting the characteristic curves for the control levers 713
11 6 8 Using the slewable spotlights 714
Manually swinging 715
Automatic load tracking 715
11 6 9 Overriding torque reduction 716
11 6 10 Displaying the operating hours 717
11 7 Working range limiter 719
11 7 1 viewing current settings 720
On the RCL dislay 720
In the CCS Startmenu 721
11 7 2 Opening the working range limiter menu 721
11 7 3 Enter limit values – for the overall height 722
11 7 4 Enter limit values – for the working radius 724
11 7 5 Enter limit values – for the slewing range 726
11 7 6 Enter limit values – for the hoist rope travel 729
11 7 7 Shutdown by working range limiter 731
11 8 Work break 733
11 8 1 In case of short work breaks 733
11 8 2 In case of work breaks of more than 8 hours 734
To secure the truck crane 734
11 9 Heating and air-conditioning system 735
11 9 1 Standard heating system 735
Switching on 735
Heating 735
Air distribution 736
Switching off 736
11 9 2 Air-conditioning system 737
Notes 737
Switching on/off 737
Cooling, automatic 738
Cooling, maximum 738
11 9 3 Auxiliary heater 739
Switching on 739
Setting the temperature 740
Setting the heating start/ heating duration 740
Switching heating start on/off 741
11 10 CraneSTAR system 742
11 10 1 Overview 742
11 10 2 Position of the components 742
12 Rigging work 743
12 1 Rigging work checklists for crane operation with themain boom 743
12 1 1 CHECKLIST: Rigging 743
12 1 2 CHECKLIST: Unrigging 749
12 2 Choice of a suitable positioning site 753
12 2 1 Determining the required load-bearing area 753
12 2 2 Safe distance from slopes and pits 756
12 2 3 Earthing the truck crane 757
12 2 4 Safe distance from overhead power lines 758
12 3 Rigging work after driving with a dolly 761
12 3 1 Switching off the boom floating position 761
12 3 2 Switching off the slewing gear freewheel 762
Before slewing 762
12 3 3 Switching off boom pre-tensioning 763
12 4 Connecting/disconnecting the hand-held control 765
12 5 Starting the engine for rigging 769
12 5 1 Starting/shutoff the engine – with the hand-held control 769
Prerequisites 769
Starting theengine 770
Turning off theengine 770
12 5 2 Starting/shutoff the engine – from the outrigger control units 771
Prerequisites 771
Starting theengine 771
Switch off theengine 771
12 6 Slewing range – only with the Standard slewing range type 773
12 6 1 Representation in the lifting capacity tables 773
12 6 2 Enabled outrigger spans 774
12 7 Outriggers – Overview – MAXbase slewing range type 775
12 7 1 Definitions 775
12 7 2 Representation in the lifting capacity tables 777
12 7 3 Enabled outrigger spans 778
12 8 Outrigger operation 783
12 8 1 CHECKLIST: Extending the outriggers 783
12 8 2 CHECKLIST: Retracting the outriggers 785
12 8 3 Preparing the truck crane 786
Driver’s cab 786
Crane cab 786
12 8 4 Setting the outrigger spans 788
For on-road driving 791
12 8 5 Extending/retracting outrigger beams 791
From the cranecab 792
From the controlunits 793
12 8 6 Moving the outrigger pads into operating/driving position 795
12 8 7 Enlarging the load-bearing area 797
12 8 8 Extending/retracting supporting cylinders 798
From the controlunits 799
From the cranecab 800
12 8 9 Levelling the truck crane on outriggers horizontally 802
Inclination indicators 802
Prerequisites 803
Manual alignment 804
Automatic alignment 804
12 8 10 Levelling the free-standing truck crane 806
12 8 11 Operating the axle raising system 808
12 8 12 Outrigger pressure display 810
12 9 Rigging/unrigging the counterweight 813
12 9 1 Information on rigging 813
When rigging 813
When unrigging 814
12 9 2 Counterweight sections 815
Version 1 815
Version 2 815
Version 3 816
12 9 3 Identification 817
12 9 4 Slinging points on the counterweight sections 818
12 9 5 CHECKLIST: Rigging the counterweight 819
12 9 6 CHECKLIST: Unrigging the counterweight 821
12 9 7 Assembling counterweight combination 822
Setting down the2 3 t base plate 823
Setting down the top couterweight section 823
Version 1 824
Version 2 832
Version 3 836
12 9 8 Counterweight hoist unit 844
Counterweight menu 844
Extending/retracting the lifting cylinders 845
Automatic mode rigging 847
Automatic mode unrigging 849
Cancel automatic mode 850
12 9 9 Removing/installing the counterweight on the turntable 851
Removing 851
Installing 852
12 9 10 Setting down counterweight for driving 853
Versions 1 and 3 853
Version 2 855
12 9 11 Slewing with rigged counterweight 855
12 10 Rigging work on the main boom 857
12 10 1 Hook block on the bumper 857
Picking up the hook block 857
Attaching the hook block 858
12 10 2 Hook block on a separate vehicle 859
Picking up the hook block 860
Setting down thehook block 860
12 10 3 Hook block, separable 862
Rigging for on- road driving 862
Rigging for crane operation 863
12 10 4 Hook block with ballast plates 864
Removing 864
Installing 865
Information on crane operation 865
12 10 5 Reeving and unreeving the hoist rope 866
Version A 866
Version B 867
Reeving the hoistrope 869
Unreeving hoistrope 873
12 10 6 Possible reevings on the main boom 874
With 6 head sheaves 874
With 8 head sheaves 877
With 9 head sheaves 880
12 10 7 Installing/removing the lifting limit switch 881
Installing the lifting limit switch 881
Removing the lifting limit switch 884
12 10 8 Locking/unlocking the lifting limit switch 886
Locking 886
Removing the lock 886
12 10 9 Anemometer and air traffic control light 887
Installing 887
Switching on/off 888
Removing 889
12 11 Other rigging work 891
12 11 1 Railings on the turntable 891
12 11 2 Folding the mirrors in and out, and adjusting them 892
12 11 3 Slinging points for personal protective equipment 893
12 11 4 Cameras for crane operation 894
Camera on mainboom 894
Camera on thehoists 897
Camera on the driver’s cab 897
Operating thecamera 898
12 11 5 Step at the crane cab 899
13 Driving with a rigged truck crane 901
13 1 Route 901
13 2 Permissible rigging modes and axle loads 902
Axle load table 902
13 2 1 To drive without a load 905
13 2 2 To drive with a load 905
13 2 3 Axle loads 906
13 3 Before driving the rigged truck crane 907
13 3 1 Check the tyre pressures and wind speed 907
13 3 2 Secure the superstructure against slewing 907
13 3 3 Putting the truck crane on the wheels – with Raise axle function 908
13 3 4 Putting the truck crane on the wheels – with the outriggers 910
13 4 Driving from the driver’s cab 913
13 4 1 Preparing to drive 913
Transmission 913
Switching on separate steering 913
Connections 913
13 4 2 Whilst driving 914
13 4 3 After driving 915
13 5 Driving from the crane cab 917
13 5 1 Preparing to drive 918
13 5 2 Opening/closing the driving menu 919
Opening the menu 919
Selecting the operating mode 919
Crane’s hydraulic system Driving mode 921
Closing menu 921
13 5 3 Steering 922
Switching on 922
Display and steering direction 922
Switching the steering direction 923
Displays whensteering 923
Separate steering 924
Normal steering mode 927
13 5 4 Operating the transmission 928
Selecting the transmission mode 928
13 5 5 Whilst driving 929
DMand RM transmission mode 929
Transmission mode D 929
Warning messages 929
13 5 6 Possible connections 930
Longitudinal/ transverse differential locks 930
13 5 7 After driving 932
14 Malfunctions during crane operation 933
14 1 Emergency stop switch 933
14 2 What to do when malfunctions occur during crane operation 934
The load can be set down 934
Load cannot besetdown 934
14 3 Warning and error messages 935
Program version 935
14 3 1 Warning messages on the CCS display 935
Meaning of the symbols 936
14 3 2 Error messages on the CCS display 940
14 3 3 Warning messages on the RCL display 942
14 4 Troubleshooting 947
14 4 1 Malfunctions on the engine 947
14 4 2 Malfunctions on the main hoist/auxiliary hoist 947
14 4 3 Malfunctions in the hoist cameras 949
14 4 4 Malfunctions in the main boom camera 949
14 4 5 Malfunctions on the derricking gear 950
14 4 6 Malfunctions in the telescoping mechanism 951
14 4 7 Malfunctions on the slewing gear 952
14 4 8 Malfunctions on the counterweight hoist unit 954
14 4 9 Malfunctions in the hydraulic system/hydraulic oil cooler 954
14 4 10 Malfunctions when operating with the hand-held control 955
14 4 11 Malfunctions when inclining the crane cab 955
14 4 12 Malfunctions when raising the axles 955
14 4 13 Malfunctions of the outriggers 956
14 4 14 Malfunctions on the turntable lock 956
14 4 15 Malfunctions on the CCS/RCL control units 957
14 4 16 Malfunctions when driving from the crane cab 957
14 4 17 Malfunctions on the CraneSTAR system 958
14 5 Emergency operations and programs 961
14 5 1 Mechanical emergency activation for retracting 962
Prior to the emergency operation, check 962
Procedure 962
Mechanical emergency activation 963
14 5 2 Telescoping emergency program 965
Telescoping emergency program menu 965
Determining the type of error 966
Error at the lengthindicator 967
Tables for approaching the locking points 971
14 5 3 Entering the current telescoping 973
14 5 4 Emergency operation with the hand-held control 975
To pre-select a power unit 976
Operating apowerunit 976
Stopping movements 977
Stopping movements in emergencies 978
Switch off theengine 978
14 5 5 Notes on slewing in emergency operation 978
For the Standard slewing range type 978
For the MAXbase slewing range type 980
14 5 6 Rotate for overridden slewing gear shutdown 981
14 6 Hydraulic emergency operation with the hand pump 983
14 6 2 Switching over the crane’s hydraulic system 984
14 6 3 Establishing the hydraulic circuits required 985
Releasing/ securing valves 985
Switching overvalves 986
For lowering 987
14 6 4 Performing emergency activation 988
14 6 5 After emergency activation 989
14 7 Hydraulic emergency operation acc to BGR159 991
14 7 1 Applications and function 991
14 7 2 CHECKLIST: Emergency operation 993
14 7 3 CHECKLIST: After emergency operation 994
14 7 4 Connecting/removing transformer – for self-sufficiency 995
Connecting 995
Removing 996
14 7 5 Switching emergency operation on/off 997
14 7 6 Connecting/removing transformer – for external energy source 998
14 7 7 Establishing the required hydraulic circuits 999
Valves at the control panel 999
For lifting/ lowering 1001
For slewing 1002
14 7 8 Performing emergency operation 1003
Slewing 1003
Derricking 1004
Lifting/lowering 1004
14 7 9 Emergency supply of another crane 1005
For emergency supply 1005
After emergency supply 1005
14 8 Fuses in the crane cab 1007
Information on changing fuses 1007
Index 1013
A 1015
B 1015
C 1016
D 1018
E 1020
F 1022
H 1022
I 1023
L 1023
M 1024
O 1025
P 1027
R 1027
S 1028
T 1029
V 1031
W 1031

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