Grove Crane GMK5150L Operating Instructions Manual 3302557 – PDF DOWNLOAD
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Grove Crane GMK5150L Operating Instructions Manual 3302557 – PDF DOWNLOAD
Pages : 968
File Type : PDF
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TABLE OF CONTENTS:
Grove Crane GMK5150L Operating Instructions Manual 3302557 – PDF DOWNLOAD
Additional pages 5
Driving with a rigged crane 3
Permissible axle loads 3
Secure the superstructure against slewing 3
CCS – Datalogger 5
Additional menu and program 5
1 Overview 15
1 1 Accidents 15
1 2 Branch offices 17
1 2 1 Manitowoc Crane Care 17
1 2 2 Dealer list 17
1 3 Warranty specifications 17
1 4 Terms used 18
1 5 Technical data 21
1 5 1 Maximum lifting capacity (DIN/ISO/EN) 21
1 5 2 Maximum lifting capacity (ASME B 30 5) 21
1 5 3 Dimensions and weights of the truck crane, axle loads 22
Dimensions 23
Weight and axleloads 23
1 5 4 Dimensions and weights of removable parts 24
Spare wheel 24
Outrigger 24
Hook blocks and hook tackle 24
Counterweight parts 25
1 5 5 Carrier 26
Engine 26
Transmission 26
Transfer case 26
Axle lines 26
Steering 26
Tyres 27
Outrigger 28
Electrical system 29
Tool 29
Towing coupling 29
Driving speeds 29
Climbing ability 29
Turning radii 30
1 5 6 Superstructure 30
Main hoist 30
Auxiliary hoist 31
Slewing gear 31
Derricking gear 31
Main boom 31
Lattice extension 31
Operating speeds 32
1 6 Documentation supplied 33
1 6 1 Questions on documentation 34
1 7 Notes on the operating manual 35
1 7 1 What do the symbols used mean? 35
1 7 2 How is the operating manual structured? 37
Division 37
Structure of thechapters 37
Structure of thepages 38
1 7 3 How do I find the information I need? 39
Cross-references example 40
1 7 4 What information is available for operations planning? 42
1 8 Conversion table for US measuring units 43
1 9 Training – Information 45
1 10 Identification 46
1 11 EC Declaration of Conformity 48
2 Basic safety instructions 51
2 1 Intended use 51
2 1 1 Improper use 52
2 2 Organisational measures 53
2 3 Personnel qualifications 55
2 4 Safety instructions for driving the truck crane 57
2 5 Safety instructions for crane operation 59
2 6 Instructions on transporting persons 63
Equipment for lifting persons 63
Personnel 64
Operation 64
Truck crane 65
3 Operating elements for driving 69
3 1 Overview of the operating elements 69
3 1 1 Exterior of the truck crane 70
3 1 2 Driver’s cab 74
Front overview 74
Rear overview 76
Behind the cover 77
3 1 3 Steering column/steering wheel 79
3 1 4 Instrument panel 81
Left/right 81
Middle 82
3 1 5 Transmission operating elements 84
3 1 6 On-board computer 85
3 1 7 Tachograph, on-board computer time correction 86
3 1 8 Heating and air-conditioning system 87
Standard 87
Auxiliary water heating system 88
Auxiliary air heater 89
3 1 9 CCS control unit 90
3 1 10 CCS display – Start menu 91
3 1 11 CCS – Overview menu groups 92
Carrier menu group 94
Suspension/level adjustment menu 95
Driving menu 96
Settings menu group 97
Menu for setting the display brightness anddate/time 98
Switch units menu 99
Information menu group 100
Operating hours menu 101
Engine/transmission error menu 102
Crane operation error menu 103
Operating additional equipment 104
Emergency operation 105
3 1 12 Outriggers control units 106
3 2 Brief description of the operating elements 107
3 2 1 Definition of direction references 107
Basic rule 107
Switches and buttons 108
3 2 2 General rules for buttons and symbols on the display 108
3 2 3 Crane control CCS 109
3 2 4 Engine 114
Steering column 114
On the steering wheel 114
Instrument panel 115
3 2 5 AdBlue system 116
Instrument panel 116
CCS display 117
3 2 6 Battery master switch 117
3 2 7 Electrical system 118
3 2 8 Transmission 119
Transmission control unit 119
Display driving mode 121
3 2 9 Reverse camera 122
3 2 10 BirdView system 270 123
3 2 11 Transfer case 125
3 2 12 Final drive 126
3 2 13 Brakes 128
Service brake 128
Parking brake 128
Additional brakes 129
3 2 14 Steering / separate steering 130
Instrument panel 130
CCS display 132
3 2 15 Suspension 134
CCS display 134
Outriggers control units 134
3 2 16 Lighting/windscreen wipers/horn 135
Steering column 135
Steering wheel 135
Instrument panel 135
CCS display 137
Roof 137
3 2 17 Level adjustment system 138
3 2 18 Tachograph/speedometer 140
Tachograph 140
Speedometer 140
3 2 19 Diagnostics 141
3 2 20 On-board computer 142
3 2 21 Push-up roof 143
3 2 22 Windows and doors 144
Window winder 144
Doors 145
3 2 23 Front flap 146
4 Starting/switching off the engine – for driving 149
4 1 Starting the engine from the driver’s cab 149
4 1 1 CHECKLIST: Starting the engine 149
4 1 2 CHECKLIST: At low temperatures 152
4 1 3 Ladders 153
Folding ladder 154
4 1 4 Refuelling 155
Fuel tank 155
AdBlue tank 157
4 1 5 Checks before starting the engine 158
At the hydraulic tank 158
Battery master switch 159
Checking the hand-held control 159
4 1 6 Switching on the ignition 159
4 1 7 Lamp test/equalisation of the switching states 160
Lamp test 160
Alignment of theswitching statuses 160
4 1 8 Display brightness 161
4 1 9 Start the engine 162
4 1 10 Inspections after starting the engine 164
Main menu and on-board computer display 164
Instrument panel 165
4 1 11 Adjust idling speed 167
4 2 Switching off the engine 169
4 2 1 At the ignition lock and with the outrigger control units 169
After turning off 169
4 2 2 With emergency stop switches 170
Resetting the emergency stop switch 170
4 3 Air intake inhibitor 171
Releasing the air intake inhibitor 171
5 Driving mode 175
5 1 Before driving 175
5 1 1 CHECKLIST: Checks before on-road driving 175
5 1 2 Checking the condition of the truck crane 181
Electrical system 181
Adjust the mirrors 181
Warning plates for vehicle width 182
Displaying vehicle height 183
Supply pressure 184
Parking brake 185
5 1 3 Adjusting the seats and steering column 187
Adjusting the driver’s seat 187
Adjusting the passenger’s seat 188
Steering column, adjusting 189
5 1 4 Switching the suspension on/off 190
Open menu 190
Switching the suspension on 191
Switching off the suspension 191
5 1 5 Setting the tachograph 192
Prerequisites 192
In the event of malfunctions 192
Setting the tachograph 193
5 1 6 Entering the time/date 197
5 1 7 Displaying and resetting operating hours 198
5 2 Operating the transmission 199
5 2 1 Switching on 199
5 2 2 Switching the transmission to the neutral position 200
5 2 3 Selecting the direction of travel and starting gear 201
Selecting the driving direction 201
Selecting the starting gear 202
5 2 4 Changing the operating mode 203
Changing to automatic mode 203
Changing to manual mode 203
5 2 5 Starting 204
5 2 6 Driving and changing gears 205
In automatic operating mode 205
In manual operating mode 206
5 2 7 Changing the driving direction 207
5 2 8 Stopping 207
Stopping for a long period of time 207
5 2 9 On the roller type dynamometer 208
5 2 10 Preheating transmission 208
5 3 Driving and turning off the truck crane 209
5 3 1 Checks while driving 209
Immediately after you start to move 209
While driving 211
5 3 2 Cruise control 212
Switching on 212
Switching off 213
5 3 3 Temposet 213
Switching on 213
Switching off 214
5 3 4 Driving downhill 215
Starting 215
Inspections when driving downhill 216
Downshifting 216
Additional brakes 217
5 3 5 Driving uphill 219
Starting 219
Driving 219
5 3 6 Warning or malfunction messages on the instrument panel 220
Meaning of thelamps 220
5 3 7 Messages on the on-board computer display 221
5 3 8 Indicator lights in the on-board computer display 223
5 3 9 Overriding the torque reduction 225
5 3 10 Warnings in the start menu 226
5 3 11 Switching the truck crane off 227
Secure it against rolling away 228
When stationary for more than 8hours 229
5 3 12 Fold-up berth 230
5 4 Off-road driving 231
Adjustments to the transmission 231
Connections 231
Changing the vehicle level 231
Rocking the vehicle free and towing 231
5 4 1 Transfer case – switching the off-road gear on/off 232
Neutral position 232
5 4 2 Longitudinal and transverse differential locks 233
5 4 3 Operating the level adjustment system 235
Open menu 235
Setting the on-road level 236
Pre-selecting suspension struts 236
Changing the vehicle level 237
Viewing the current inclination 237
Exiting the menu 238
5 4 4 Freeing an immobilized truck crane 239
Rocking the truck crane free 239
Towing free to thefront 240
Towing free in reverse gear 240
5 5 Separate steering 241
5 5 1 Switching to separate steering 242
5 5 2 Switching to normal steering mode 245
5 5 3 Switching units of measure 246
5 6 Heating and air-conditioning system 247
5 6 1 Standard heating system 247
Switching on 247
Heating 247
Air distribution 248
Examples 249
Switching off 249
5 6 2 Air-conditioning system 250
Information 250
Switching on/off 250
Cooling 251
Drying 251
5 6 3 Auxiliary water heating system 253
Preheating theengine 253
Preheating the driver’s cab 254
Switching on 254
Adjusting thedateand time 256
Storing the heating start 257
5 6 4 Auxiliary air heater 259
Switching on 259
Setting the heating level 260
Setting the day and time 261
Setting the preselection time 261
Deleting preselection times 263
Switching off 263
5 7 Towing a trailer 265
Effects on the axleloads 265
Coupling thetrailer 266
Connecting the supply lines 267
Removing supplylines 268
Uncoupling thetrailer 268
Checking the braking force 270
6 Driving modes 273
6 1 Driving modes 273
Information on the axle loads 273
6 1 1 How to use the tables: 274
6 1 2 Table for a maximum axle load of 12 t (26,500 lbs) 275
385/95 R25 tyres 275
445/95 R25 tyres 276
525/80 R25 tyres 277
6 1 3 Maximum permitted speeds with an axle load of over 12 t (26500 lbs) 278
6 2 Weighing the truck crane 279
Axle groups 280
Weighing procedure 281
Evaluation 282
6 3 Rigging work for driving with a trailer 283
6 3 1 Switching on the slewing gear freewheel 284
6 3 2 Switching on the boom floating position 285
6 3 3 Switching on boom pre-tensioning 286
6 3 4 Raising/lowering the 3rd axle line for towing a trailer 287
Lifting 287
Lowering 287
6 4 Rigging the main boom 289
Additional equipment required 289
6 4 1 CHECKLIST: removing the main boom 290
Prerequisites 290
Checklist 290
6 4 2 CHECKLIST: installing the main boom 293
Prerequisites 293
Checklist 293
6 4 3 Slinging the main boom 296
Marking 296
Installing the lifting gear 296
Removing the lifting gear 297
6 4 4 Switching the pressure relief on/off 298
6 4 5 Retracting/fitting the derricking cylinder head pin 299
Retracting the derricking cylinder head axle 300
Fitting the derricking cylinder head axle 301
6 4 6 Extending/retracting the boom pivot pin 302
Before pulling itout 302
After pushing it in 302
Pulling out the pivot pin 303
Pushing the pivotpin in 304
6 4 7 Removing/attaching the clamps 306
6 4 8 Disconnecting/connecting hydraulics/electrical 307
Disconnecting 307
Connecting 308
6 4 9 Aligning the connecting points 309
6 4 10 Securing/releasing the derricking cylinder 310
6 4 11 Transporting the main boom 310
6 4 12 Inspections after main boom mounting 311
6 5 Installing/removing 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 connection 317
6 5 6 Establishing/disconnecting 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
7 Transport 325
7 1 Transport with transport vehicle 325
7 1 1 CHECKLIST: Checks before transport 326
7 1 2 Drive the truck crane on to the transport vehicle 328
Driving on 329
Lashing 329
7 2 Transport by ship 330
8 Malfunctions in driving mode 331
8 1 Emergency stop switches 331
8 2 What to do when a malfunction occurs in road traffic 333
8 3 Towing away the truck crane 335
8 3 1 Towing after engine/transmission damage 336
Compressed-air supply 336
Electric power supply 336
On the transmission 337
Axle drives 337
Parking brake 338
Towing the truck crane out of the danger area 339
Longer towing distances 339
8 3 2 Tow starting 339
8 4 Other emergency operations 341
8 4 1 Externally starting the truck crane 341
8 4 2 Battery charger 342
Prerequisites 342
8 5 Wheels and tyres 343
8 5 1 Wheel change 343
Removing a damaged wheel 344
On the spare wheel holder 344
Mounting a wheel 345
8 5 2 Inflating the tyres yourself 347
Connecting the filling hose 347
Inflating the tyres 348
Remove the fillinghose 348
8 6 Tilting/lowering the driver’s cab 349
8 6 1 Prerequisites and information on tilting 349
8 6 2 Tilting/lowering the driver’s cab 350
Operating the hand pump 350
Tilting the driver’scab 351
Lowering the driver’s cab 352
8 7 Fuses on the carrier 355
Information on replacing fuses 355
8 7 1 Fuses in the driver’s cab 356
8 7 2 Fuses in the battery box 362
8 8 Troubleshooting 363
8 8 1 Malfunctions on the engine 363
When operating with the dual tank 365
8 8 2 Faults on the Adblue system 365
8 8 3 Malfunctions of the differential locks 366
8 8 4 Malfunctions in the transmission 367
8 8 5 Malfunctions of the steering 368
8 8 6 Malfunctions of the service brake 369
8 8 7 Malfunctions on the suspension 370
8 8 8 Malfunctions of the level adjustment system 370
8 8 9 Malfunctions in the hydraulic system/hydraulic oil cooler 370
8 9 CCS warning/error message 371
Symbols in the display area 371
8 9 1 Engine/transmission error menu 375
Open menu 375
Exiting the menu 375
8 10 Procedure during malfunctions 377
8 10 1 Procedure during engine malfunctions 377
8 10 2 Procedure during transmission malfunctions 378
9 Operating elements for crane operation 383
9 1 Overview of the operating elements 383
9 1 1 Exterior of the truck crane 384
9 1 2 Crane cab 388
Side panel 390
Crane cab, rear 392
9 1 3 Control panels 394
Left 394
Right 395
9 1 4 Control lever configuration 396
Version 1 396
Version 2 397
9 1 5 CCS control unit 398
9 1 6 CCS – Start menu 401
9 1 7 CCS – Overview menu groups 402
Superstructure menu group 406
Superstructure lock sub-menu 407
Counterweight menu 408
Outrigger menu 409
Outrigger support beam menu 411
Outrigger cylinders menu 412
Menu group Teleautomation 414
Telescoping full automation menu 415
Telescoping semi- automation menu 416
Manual telescoping menu 417
Main boom configuration menu 418
Active working range limiter menu group 419
Overall height menu 420
Working radius menu 421
Slewing angle menu 422
Hoist rope travel limitation menu 423
Information menugroup 424
Hydraulic pressure and fuel consumption menu 425
Engine/Driving menu group 427
Driving mode menu 428
Economy mode menu 430
Remote control menu 431
Heating/air-conditioning menu 432
Spotlights menu 433
Telescoping emergency program menu group 434
Unknown telescoping menu 435
Telescoping emergency program menu 436
Settings menu group 437
Crane cab menu 438
Menu for setting the display brightness and date/ time 439
Switch units menu 440
Set control lever characteristic curve menu 441
Power unit speeds menu 442
Information menu group 443
Operating hours menu 444
Engine/transmission error menu 445
Crane operation error menu 446
Program version menu 447
Operating additional equipment 448
9 1 8 RCL control unit 449
9 1 9 RCL – menu groups 452
Enter rigging mode menu 454
Monitoring menu 455
Lifting capacity table menu 456
9 1 10 Hand-held control 457
9 1 11 Outriggers control units 458
Button 458
Outrigger button 459
Inclination and outrigger pressure display 460
Raise axle display 461
9 2 Brief description of the operating elements 463
9 2 1 Definition of direction references 463
Basic rule 463
Switches 463
9 2 2 General rules for buttons and symbols on the display 464
9 2 3 Crane control CCS 465
9 2 4 Engine 472
Side panel 472
CCS display 472
Economy mode menu 473
Left control lever 473
9 2 5 AdBlue system 474
CCS display 474
9 2 6 Seat contact switch and dead man’s switch 475
9 2 7 Outrigger 477
Right-hand control panel 477
Left-hand controlpanel 477
In the Outrigger menu 478
At the outrigger control units 481
9 2 8 Inclination indicators 483
9 2 9 Raise axle 484
Outriggers control units 484
CCS display 485
9 2 10 Outrigger pressure displays 486
Outrigger submenu 486
Outriggers controlunits 486
9 2 11 Anemometer displays 486
9 2 12 Counterweight menu 488
Counterweight submenu 488
9 2 13 Main hoist 492
Control panels 492
CCS display 492
9 2 14 Auxiliary hoist 494
Control panels 494
CCS display 494
9 2 15 Slewing gear 496
Control panels 496
CCS display 497
9 2 16 Derricking gear 498
Control panels 498
CCS display 499
9 2 17 Telescoping mechanism 500
Control panels 500
CCS display 500
Telescoping full automation menu 501
Telescoping semi- automation menu 502
Manual telescoping menu 504
Main boom configuration menu 507
9 2 18 Hydraulic system 508
9 2 19 Superstructure lock/house lock menu 509
Superstructure lock 509
Houselock 510
9 2 20 Remote control 511
9 2 21 Rated capacity limiter (RCL) 512
Control unit control console RCL 512
Display RCL 513
Enter rigging mode menu 514
Monitoring menu 518
Lifting capacity tables menu 522
RCL override – version A 523
RCL override – Version B 524
9 2 22 Electrical system 525
9 2 23 Lighting, windscreen wiper/washing system 526
Lighting 526
Windscreen wiper/washing system 528
9 2 24 Hand-held control 530
Sockets for hand-held control 530
Engine control panel 531
Horn 531
Outriggers control panel 532
9 2 25 Windows and doors 534
Windows 534
Rear window 534
Crane cab door 535
9 2 26 Diagnostics 536
9 3 Short description of the operating elements – driving from the crane cab 537
9 3 1 Driving mode menu 537
9 3 2 Transmission 538
9 3 3 Final drive 539
9 3 4 Brakes 540
CCS display 540
Side panel from above 541
9 3 5 Steering 542
CCS display 542
Separate steering 543
Control panels 545
10 Starting/switching off the engine – for crane operation 549
10 1 When starting the engine for the first time in the day 549
10 2 Starting the engine – from the crane cab 551
10 2 1 Check the fuel level and AdBlue level 551
Fuel 551
AdBlue 551
10 2 2 Checks before starting the engine 552
Checks on thecarrier 552
Checking the hand-held control 552
At the hydraulic tank 552
10 2 3 Switching on the ignition 553
10 2 4 Alignment of the switching statuses 554
Alignment of theswitching statuses 554
10 2 5 Display – setting the brightness 555
10 2 6 Start the engine 556
10 2 7 Inspections after starting the engine 557
10 2 8 Adjust idling speed 558
10 3 Starting the engine – with the hand-held control 559
10 4 Switching off the engine 561
10 4 1 At the ignition lock and with hand-held control 561
After turning off 561
10 4 2 With the idling button 561
10 4 3 Using the emergency stop switches 562
Resetting the emergency stop switch 562
11 Crane operation 565
11 1 Before operating the crane 565
11 1 1 CHECKLIST: Checks before operating the crane 565
11 1 2 Checking the condition of the truck crane 569
Fuel tank auxiliary heater 569
Visual inspection 569
Checking the position of the hoist ropes 570
Checking the electrical system 571
11 1 3 Adjusting the crane cab seat and front control panel 572
Crane cab seat 572
Front panel 573
11 1 4 Checking the safety equipment 574
Rated capacity limiter 574
Lifting limit switch 574
Emergency stop switches 575
Seat contact switch 576
11 1 5 Earthing the load 577
11 1 6 Preheating the hydraulic oil 578
Prerequisites 578
Preheating 578
11 1 7 Locking/unlocking the superstructure 579
Locking points 579
Locking the superstructure 580
Unlocking the superstructure 580
11 1 8 Switching the houselock on/off 581
Switching on the houselock 581
Switching off the houselock 583
11 2 Operation of the rated capacity limiter 585
11 2 1 Switch on the RCL 586
Switching on 586
Brightness of thedisplays 588
Temperature on the display 588
11 2 2 Enter rigging mode 589
Entering individual components 590
Entering the RCLcode 595
Enter the reeving 596
Accepting the rigging mode 596
11 2 3 Checks before operating the crane 598
Open menu 598
Checks 598
11 2 4 Displays during crane operation 601
11 2 5 RCL early warning 604
11 2 6 RCL shutdown 604
Shutdown due tooverload 604
11 2 7 Display in the event of errors 606
11 2 8 RCL override – version A 607
Overview status display 607
When rigging 608
To raise the boom 609
In emergencies 610
11 2 9 RCL override – version B 611
11 2 10 Displaying the lifting capacity tables 612
11 2 11 Setting the time/date 614
11 3 Crane operation with main boom 615
11 3 1 Checks during crane operation 615
Horizontal alignment 615
Safe distances 615
Checking the windspeed 616
11 3 2 Permissible slewing ranges and working positions 617
360 slewing range 617
Working position 0 to the rear 617
180 to the front rigging position 617
11 3 3 Main hoist 619
Switching on the main hoist 620
Lifting and lowering 620
Maximum permissible hoist rope speed 620
Switching off the main hoist 621
11 3 4 Auxiliary hoist 623
Switching on the auxiliary hoist 623
Lifting and lowering 624
Maximum permissible hoist rope speed 624
Switching off the auxiliary hoist 625
11 3 5 Lifting limit switch and lowering limit switch 627
Lifting limit switch 627
Lowering limit switch 629
11 3 6 Derricking gear 630
Switching on the derricking gear 630
Maximum permissible derricking speed 630
Raising and lowering 631
Re-enable raising function 632
Switching off the derricking gear 632
11 3 7 Telescoping mechanism 634
Overview 635
Telescoping process 636
Assignment fordisplay 638
Fixed length, intermediate length, telescoping length 639
Telescoping 640
Telescoping sequence 640
Checks before starting work 641
Switching on thetelescoping mechanism 642
Function of the control lever 642
Switching off thetelescoping mechanism 644
Manual telescoping 645
Checking the initial position 645
Unlocking the telescoping cylinder 647
Extending/ retracting the telescoping cylinder 649
Locking the telescoping cylinder 650
Unlocking the telescopic section 651
Telescoping the telescopic section 652
Locking the telescopic section 653
Locking the telescopic section for on-road driving 654
Telescoping with semi-automaton 654
Telescoping with full automation 657
Telescoping withmain boom configuration 658
11 3 8 High-speed mode 659
Derricking gear telescoping mechanism 659
Hoists 659
11 3 9 Slewing gear 661
Switching on the slewing gear 661
Releasing the slewing gear brake 661
Applying the slewing gear brake 662
Slewing 662
Releasing locked slewing gear 662
Maximum permitted slewing speed 663
Braking the slewing movement 664
Slewing gear freewheel 664
Switching off the slewing gear 665
11 3 10 Possible movement combinations 666
11 4 Settings and displays for crane operation 667
11 4 1 Inclining the crane cab 667
11 4 2 Adjust idling speed 668
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 668
11 4 4 Limiting the power unit speeds 669
11 4 5 Economy mode 670
Switching on 670
Switch off/exit 672
11 4 6 Switching units of measure 673
11 4 7 Setting the characteristic curves for the control levers 674
11 4 8 Using the slewable spotlights 675
Manually swinging 675
Automatic load tracking 676
11 4 9 Overriding the torque reduction 677
11 4 10 Displaying the operating hours 678
11 4 11 Warnings in the start menu 680
Meaning of the symbols 680
11 5 Working range limiter 684
11 5 1 Viewing current settings 685
11 5 2 Opening the working range limiter menu 685
11 5 3 Entering limit values 688
Overall height 688
Working radius 689
Slewing angle 689
Hoist rope travel limitation 690
11 5 4 Entering limit values manually 691
Limit values 691
11 5 5 Switching monitoring functions on/off 693
11 5 6 Shutdown by working range limiter 694
11 6 Work break 695
11 6 1 In case of short work breaks 695
11 6 2 In case of work breaks of more than 8 hours 696
To secure the truck crane 696
11 7 Heating and air-conditioning system 697
11 7 1 Standard heating system 697
Switching on 697
Heating 697
Air distribution 698
Switching off 698
11 7 2 Air-conditioning system 699
Information 699
Switching on/off 699
Cooling, automatic 700
Cooling, maximum 700
11 7 3 Auxiliary heater 701
Switching on 701
Adjusting the temperature 702
Setting the heating start/ heating duration 702
Switching heating start on/off 703
11 8 CraneSTAR system 704
11 8 1 Overview 704
11 8 2 Position of the components 704
12 Rigging work 707
12 1 Rigging work checklists for crane operation with the main boom 707
12 1 1 CHECKLIST: Rigging 707
12 1 2 CHECKLIST: Unrigging 713
12 2 Selecting the suitable site 717
12 2 1 Determining the required load-bearing area 717
12 2 2 Safe distance from slopes and pits 720
12 2 3 Earthing the truck crane 721
12 2 4 Safe distance from overhead power lines 722
12 3 Rigging work after driving with a trailer 725
12 3 1 Switching off the boom floating position 725
12 3 2 Switching off the slewing gear freewheel 726
Before slewing 726
12 3 3 Switching off boom pre-tensioning 727
12 4 Connecting/disconnecting the hand-held control 729
12 5 Starting the engine for rigging 731
12 5 1 Starting/turning off the engine with the hand-held control 731
Prerequisites 731
Start the engine 732
Switching off theengine 732
12 5 2 Starting/switching off the engine from the outrigger control units 733
Prerequisites 733
Start the engine 733
Switching off theengine 733
12 6 Outrigger 735
12 6 1 CHECKLIST: Extending the outriggers 735
12 6 2 CHECKLIST: Retracting the outriggers 737
12 6 3 Permissible outrigger spans 738
12 6 4 Preparing the truck crane 739
Driver’s cab 739
Crane cab 739
12 6 5 Setting the spans 741
For on-road driving 743
12 6 6 Extending/retracting outrigger beams 745
From the control units 746
From the cranecab 747
12 6 7 Moving the outrigger pads into operating/driving position 749
12 6 8 Enlarging the load-bearing area 751
12 6 9 Extending/retracting supporting cylinders 752
From the controlunits 753
From the cranecab 754
12 6 10 Levelling the truck crane on outriggers 756
Inclination indicators 756
Prerequisites 757
Manual alignment 758
Automatic alignment 759
12 6 11 Levelling the free-on-wheels truck crane 760
12 6 12 Outrigger pressure display 762
12 7 Rigging/unrigging the counterweight 763
12 7 1 Information on rigging 763
When rigging 764
When unrigging 765
12 7 2 Counterweight sections 766
Version 1 766
Version 2 766
Version 3 767
12 7 3 Identification 768
12 7 4 Slinging points on the counterweight sections 769
12 7 5 CHECKLIST: Rigging the counterweight 771
12 7 6 CHECKLIST: Unrigging the counterweight 773
12 7 7 Assembling counterweight versions 775
Setting down the 2 3 t base plate 776
Setting down the top counterweight section 776
Version 1 777
Version 2 785
Version 3 789
12 7 8 Counterweight hoist unit 797
Counterweight menu 797
Extending/ retracting the lifting cylinders 798
Automatic moderigging 800
Automatic mode unrigging 802
Cancel automatic mode 803
12 7 9 Removing/installing the counterweight on the turntable 804
Removing 804
Installing 805
12 7 10 Setting down counterweight for driving the truck crane 806
Version 1 and 3 806
Version 2 808
12 7 11 Slewing with the rigged counterweight 809
12 8 Rigging work on the main boom 811
12 8 1 Hook block on the bumper 811
Picking up the hook block 811
Attaching the hook block 812
12 8 2 Hook block on a separate vehicle 813
Picking up the hook block 814
Setting down the hook block 814
12 8 3 Hook block, separable 816
Rigging for on-road driving 816
Rigging for crane operation 817
12 8 4 Reeving and unreeving the hoist rope 818
Version A 818
Version B 819
Reeving the hoist rope 821
Unreeving hoist rope 825
12 8 5 Possible reeving methods on the main boom 826
With 6 head sheaves 826
With 8 head sheaves 828
With 9 head sheaves 832
12 8 6 Installing/removing the lifting limit switch 833
Installing lifting limit switch 833
Removing the lifting limit switch 836
12 8 7 Locking/unlocking the lifting limit switch 838
Locking 838
Unlocking 838
12 8 8 Anemometer and air traffic control light 839
Installing 839
Switching the air traffic control light on and off 840
Removing 840
12 9 Other rigging works 843
12 9 1 Folding the mirrors in and out, and adjusting them 843
12 9 2 Cameras for crane operation 844
Camera on mainboom 844
Camera on thehoists 846
Camera on the driver’s cab 846
Operating the camera 847
12 9 3 Railings on the turntable 848
12 9 4 Step for the crane cab 849
12 9 5 Slinging points for personal protective equipment 850
13 Driving with a rigged truck crane 853
13 1 Driving path 853
13 2 Permissible rigging modes and axle loads 854
Axle load table 855
13 2 1 To drive without a load 856
13 2 2 To drive with a load 857
13 2 3 Axle loads 857
13 3 Before driving the rigged truck crane 858
13 3 1 Check the tyre pressures and wind speed 858
13 3 2 Securing the superstructure against slewing 858
13 3 3 Putting the truck crane on the wheels 859
13 4 Driving from the driver’s cab 861
13 4 1 Preparing to drive 861
Transmission 861
Switching on separate steering 861
Connections 861
13 4 2 While driving 862
13 4 3 After driving 863
13 5 Driving from the crane cab 865
13 5 1 Preparing to drive 866
13 5 2 Opening/closing the Driving menu 866
Opening 866
Crane hydraulic system on/off 867
Closing 868
13 5 3 Steering 869
Switching on 869
Steering direction 869
Displays when steering 870
Separate steering 870
Normal steering mode 874
13 5 4 Operating the transmission 875
Selecting the transmission mode 875
13 5 5 While driving 876
DMand RM transmission mode 876
Transmission mode D 876
Warning messages 876
13 5 6 Possible connections 877
Longitudinal/ transverse differential locks 877
13 5 7 After driving 879
14 Malfunctions during crane operation 883
14 1 Emergency stop switches 883
14 2 What to do when malfunctions occur during crane operation 885
The load can be set down 885
Load cannot be set down 885
14 3 Fuses in the crane cab 887
Information on replacing fuses 887
14 4 Troubleshooting 892
14 4 1 Malfunctions on the engine 892
14 4 2 Malfunctions when operating with the hand-held control 892
14 4 3 Malfunctions on the turntable lock 893
14 4 4 Malfunctions when inclining the crane cab 893
14 4 5 Malfunctions on the main hoist 894
14 4 6 Malfunctions in the telescoping mechanism 895
14 4 7 Malfunctions in the hoist cameras 896
14 4 8 Malfunctions in the main boom camera 896
14 4 9 Malfunctions on the derricking gear 897
14 4 10 Malfunctions on the slewing gear 898
14 4 11 Malfunctions on the counterweight hoist unit 899
14 4 12 Malfunctions in the hydraulic system/hydraulic oil cooler 900
14 4 13 Malfunctions when driving from the crane cab 900
14 4 14 Malfunctions of the outriggers 901
14 4 15 Troubleshooting the crane control 903
General malfunctions 904
Symbols in the error or information display areas 904
Displays in the Error menu 908
14 4 16 Malfunctions on the CraneSTAR system 910
14 5 Emergency operations and programs 911
14 5 1 Mechanical emergency activation for retracting 912
Prior to the emergency activation, check 912
Procedure 912
Mechanical emergency activation 913
14 5 2 Telescoping emergency program 915
Open the Emergency program submenu 915
Determining the type of error 916
If there is an error on the length indicator 917
Tables for approaching the locking points 921
14 5 3 Entering the current telescoping 923
14 5 4 Emergency operation with the hand-held control 925
Preparations 925
Pre-selecting a power unit 926
Operating apowerunit 926
Stopping movements 927
Stopping movements in emergencies 928
Switching off theengine 928
14 6 Hydraulic emergency operation 929
Switching over valves 929
Releasing/ securing valves 930
For lowering 931
14 6 1 Performing emergency activation 933
14 6 2 After the emergency activation 933
14 6 3 Operating principle of emergency operation BGR 159 934
14 6 4 Connecting/disconnecting hoses 935
Establishing connections 935
Disconnecting connections 936
14 6 5 Switching emergency operation on/off 937
14 6 6 Establishing the hydraulic circuits required 937
Switching over valves 937
For lifting/ lowering 939
For slewing 940
14 6 7 Performing emergency operation 941
Slewing 941
Derricking 942
Lifting/lowering 942
14 6 8 After emergency operation 943
Switching off emergency operation 943
Switching over to crane operation 943
Disconnecting thehoses 943
14 6 9 Emergency supply of another crane 944
For emergency supply 944
After emergency supply 944
15 Index 947
A 949
B 949
C 950
D 953
E 955
F 956
H 956
I 957
L 958
M 958
O 959
P 960
R 961
S 962
T 963
V 965
W 965
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