Manitowoc Grove Crane GMK 5250XL-1 Operating instructions Manual 3302983 – PDF DOWNLOAD
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Manitowoc Grove Crane GMK 5250XL-1 Operating instructions Manual 3302983 – PDF DOWNLOAD
Language : English
Pages : 1014
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Manitowoc Grove Crane GMK 5250XL-1 Operating instructions Manual 3302983 – PDF DOWNLOAD
Operating Instructions 1
Table of content 5
General 35
1 Overview 35
1 1 Accidents 35
1 2 Branch offices 37
1 2 1 Manitowoc Crane Care 37
1 2 2 Dealer list 37
1 3 Warranty specifications 37
1 4 Terms used 38
1 5 Technical data 41
1 5 1 Maximum lifting capacity (DIN/ ISO/ EN) 41
1 5 2 Dimensions and weights of the truck crane, axle loads 42
Dimensions 43
Weight and axle loads 43
1 5 3 Dimensions and weights of removable parts 44
Spare wheel 44
Outriggers 44
Main boom 45
Hook blocks and hook tackle 45
Hook blocks, split 46
Auxiliary hoist 47
Counterweight parts 47
Version 1 47
Version 2 48
1 5 4 Carrier 49
Engine 49
Transmission 49
Transfer case 49
Axle lines 50
Steering 50
Tyres 50
Electrical system 50
Tool 51
Towing couplings 51
Driving speeds 51
Climbing ability 51
Outriggers 52
Turning radii 53
1 5 5 Superstructure 54
Main hoist 54
Auxiliary hoist 54
Slewing gear 54
Derricking gear 55
Main boom 55
Lattice extension 55
Operating speeds 56
Noise emission 56
1 6 Documentation supplied 57
1 6 1 Questions on documentation 58
1 7 Notes on the operating manual 59
1 7 1 What do the symbols used mean? 59
1 7 2 How is the operating manual structured? 61
Division 61
Structure of the chapters 61
Structure of the pages 62
1 7 3 How do I find the information I need? 63
Cross-references example 64
1 7 4 What information is available for operations planning? 66
1 8 Conversion table for US measuring units 67
1 9 Training – Information 69
1 10 Identification 70
1 11 EC Declaration of Conformity 72
2 Basic safety instructions 73
2 1 Intended use 73
2 1 1 Improper use 74
2 2 Organisational measures 75
2 3 Personnel qualifications 77
2 4 Safety instructions for driving the truck crane 78
2 5 Safety instructions for crane operation 79
2 6 Instructions on transporting persons 82
Equipment for lifting persons 82
Personnel 83
Operation 83
Truck crane 84
Driving 85
3 Operating elements for driving 85
3 1 Overview of the operating elements 85
3 1 1 Exterior of the truck crane 86
3 1 2 Driver’s cab 90
Overview 90
Behind the cover 94
In the rear of the driver’s cab 94
3 1 3 Steering column/steering wheel 95
3 1 4 Instrument panel 97
Left/right 97
Middle 98
3 1 5 Transmission operating elements 100
3 1 6 On-board computer 101
3 1 7 Tachograph 102
3 1 8 Heating/Air-conditioning system 103
Standard heating system 103
Auxiliary water heating system 104
Auxiliary air heater 105
3 1 9 CCS control unit 106
3 1 10 CCS – Menu-independent displays 108
3 1 11 CCS – Start menu 109
3 1 12 CCS – Overview of menu groups 110
3 1 13 Carrier menu group 112
Suspension/level adjustment menu 113
Driving menu 114
Exhaust system menu 115
Air intake inhibitor menu 116
3 1 14 Settings menu group 117
Set display brightness and date/time menu 118
3 1 15 Information menu group 119
Operating hours menu 120
Engine/transmission error menu 121
Crane operation error menu 122
3 1 16 Various controls menu group 123
3 1 17 Emergency operations menu group 124
3 1 18 Outrigger control units 125
3 2 Brief description of the operating elements 127
3 2 1 Definition of direction information 128
Basic rule 128
Switches and buttons 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 (DEF) system/Exhaust gas emission control system/ Regeneration 132
Instrument panel 132
CCS display 133
3 2 5 Air intake inhibitor 135
3 2 6 Battery master switch 136
3 2 7 Electrical system 137
3 2 8 CCS crane control system 138
3 2 9 Transmission 140
Transmission control unit 140
Driving mode display 141
3 2 10 Reverse camera 143
3 2 11 BirdView system 270° 144
3 2 12 Transfer case 146
3 2 13 Final drive 147
3 2 14 Brakes 149
Service brake 149
Additional brakes 149
Parking brake 150
3 2 15 Steering/separate steering 152
Instrument panel 152
CCS display 154
3 2 16 Suspension 156
CCS display 156
3 2 17 Lighting/windscreen wipers/horn 157
Steering column 157
Steering wheel 157
Instrument panel 157
CCS display 160
Roof 160
3 2 18 Level adjustment system 161
3 2 19 Tachograph/speedometer 163
Tachograph 163
Cover 163
Speedometer 163
3 2 20 Diagnostics 164
3 2 21 On-board computer 165
3 2 22 Windows, doors, keys 167
Window winder 167
Doors 168
Keys 168
3 2 23 Ladders and access ladders 169
Access ladders 169
Ladders 170
3 2 24 Front flap 172
4 Starting/switching off the engine – for driving 173
4 1 Starting the engine from the driver’s cab 173
4 1 1 CHECKLIST: Starting the engine 174
4 1 2 CHECKLIST: At low temperatures 177
4 1 3 Refuelling 178
Standard tank 178
Dual- tank 179
AdBlue 180
4 1 4 Checks before starting the engine 181
At the hydraulic tank 181
Battery master switch 182
Checking the hand-held control 182
4 1 5 Switching on the ignition 183
4 1 6 Lamp test/comparison of the switching states 184
Lamp test 184
Comparison of the switching states 184
4 1 7 Display – Setting the brightness 185
4 1 8 Starting the engine 186
4 1 9 Starting the engine – at the outrigger control units 188
Prerequisites 188
Starting the engine 188
4 1 10 Checks after starting the engine 189
Start menu and on-board computer 189
Instrument panel 190
4 1 11 Monitoring elements 192
Instrument panel 192
4 1 12 Setting the idling speed 193
4 2 Switching off the engine 195
4 2 1 On the ignition lock/on the outrigger control units 195
After switching off 195
4 2 2 Using the emergency stop switches 196
Resetting the emergency stop switch 196
4 3 Air intake inhibitor 197
Opening the air intake inhibitor 197
5 Driving 199
5 1 Before driving 199
5 1 1 CHECKLIST: Checks before on-road driving 199
5 1 2 Checking the condition of the truck crane 205
Electrical system 205
Adjusting the mirrors 205
Warning plates for vehicle width 207
Vehicle height display 207
Supply pressure 208
Parking brake 209
5 1 3 Adjusting the seat and the steering column 210
Driver’s seat 210
Passenger’s seat 211
Adjusting the steering column 212
5 1 4 Switching the suspension on/off 213
Opening the menu 213
Switching on the suspension 214
Switching off the suspension 214
5 1 5 Setting the tachograph 215
Prerequisites 215
In the event of malfunctions 215
Setting the tachograph 216
5 1 6 Setting the time 220
5 1 7 Displaying and resetting operating hours 221
5 2 Operating the transmission 223
5 2 1 Switching on 223
5 2 2 Shifting the transmission to neutral position 224
5 2 3 Selecting the direction of travel and starting gear 225
Selecting the driving direction 225
Selecting the starting gear 226
5 2 4 Changing the operating mode 227
Changing to automatic mode 227
Changing to manual mode 227
5 2 5 Starting driving 228
5 2 6 Driving and changing gears 229
In automatic operating mode 229
In manual operating mode 230
5 2 7 Changing the driving direction 231
5 2 8 Stopping the truck crane 231
Stopping for a long period of time 231
5 2 9 On the roller type dynamometer 232
5 2 10 Preheating the transmission 232
5 3 Driving and parking the truck crane 233
5 3 1 Checks while driving 233
Immediately after you start to move 233
While driving 235
5 3 2 Cruise control 237
Switching on 237
Switching off 237
5 3 3 Temposet 238
Switching on 238
Switching off 238
5 3 4 Driving downhill 239
Starting driving 239
Checks when driving downhill 240
Downshifting 240
Additional brakes 241
5 3 5 Driving uphill 242
Starting driving 242
Driving 242
5 3 6 Torque reduction 243
AdBlue (DEF) tank 243
System malfunction 244
5 3 7 Overriding torque reduction 246
5 3 8 Cleaning the exhaust system 247
Automatic cleaning 247
Manual cleaning 248
Disabling cleaning 250
5 3 9 Parking the truck crane 251
Securing against rolling away 251
When stationary for more than 8 hours 252
5 3 10 Folding berth 253
5 4 Off-road driving 255
Adjustments to the transmission 255
Connections 255
Changing the vehicle level 255
Rocking the vehicle free and towing 255
5 4 1 Transfer case – switching the off-road gear on/off 256
5 4 2 Longitudinal and transverse differential locks 257
5 4 3 Operating the level adjustment system 259
Opening the menu 259
Setting the on-road level 260
Pre-selecting suspension struts 260
Changing the vehicle level 261
Viewing the current inclination 261
Exiting the menu 262
5 4 4 Freeing a stuck truck crane 263
Rocking the truck crane free 263
Towing free forwards 264
Towing free in reverse gear 264
5 5 Separate steering 265
5 5 1 Switching to separate steering 265
Manual 266
Automatic 267
5 6 Heating and air-conditioning system 269
5 6 1 Standard heating system 269
Switching on 269
Heating 269
Air distribution 270
Examples 271
Switching off 271
5 6 2 Air-conditioning system 272
Notes 272
Switching on/off 272
Cooling 273
Drying 273
5 6 3 Auxiliary water heater 274
Preheating the engine 274
Preheating the driver’s cab 275
Switching on the auxiliary heater 276
Switching off the auxiliary heater 277
Setting time and weekday 277
Saving automatic heating start 278
Error messages 280
5 6 4 Auxiliary air heater 282
Switching on 282
Temperature 283
Switching off 283
Other functions 283
5 6 5 Radio 284
5 7 Towing a trailer 285
Effects on the axle loads 285
Coupling the trailer 286
Connecting the supply lines 287
Removing the supply lines 288
Uncoupling the trailer 288
Checking the braking force 290
6 Driving modes and rigging for on-road driving 291
6 1 Driving modes 291
Information about the axle loads 291
6 1 1 Information on how to use the tables 292
6 1 2 Tables for a maximum axle load of 12 t 293
For tyres 385/95 R25 293
For tyres 445/95 R25 294
Fort tyres 525/80 R 25 295
6 1 3 Maximum permitted speeds with an axle load greater than 12 t 296
6 2 Weighing the truck crane 297
Axle groups 298
Weighing procedure 299
Evaluation 300
6 3 Rigging work for driving with a dolly 301
6 3 1 Switching on the slewing gear freewheel 302
6 3 2 Switching on the boom floating position 303
6 3 3 Switching on boom pre-tensioning 304
6 3 4 3rd Axle raising/lowering 305
6 4 Rigging the main boom 307
Additional equipment required 307
6 4 1 CHECKLIST: Removing the main boom 308
Prerequisites 308
Checklist 308
6 4 2 CHECKLIST: Mounting the main boom 310
Prerequisites 310
Checklist 310
6 4 3 Slinging the main boom 312
Marking 312
Installing the lifting gear 312
Removing the lifting gear 313
6 4 4 Removing/inserting the derricking cylinder head axle 314
Operating the lifting device 314
Pulling the derricking cylinder head axle 315
Fitting the derricking cylinder head axle 316
6 4 5 Retracting/extending the boom pivot pin 317
Before retracting 317
After extending 318
Retracting/ extending the pivot pin 319
6 4 6 Disconnecting/connecting hydraulic/electrical connections 320
Disconnecting 320
Establishing 321
6 4 7 Lifting the main boom off/onto the turntable 322
Lifting from the turntable 322
Lifting onto the turntable 323
6 4 8 Aligning the connecting points 323
6 4 9 Transporting the main boom 324
6 4 10 Checks after installing the main boom 325
6 5 Removing/installing the outrigger beams 327
6 5 1 CHECKLIST: Removing the outrigger beams 328
6 5 2 CHECKLIST: Installing the outrigger beams 330
6 5 3 Preparations – for removal 332
6 5 4 Preparations – for installation/removal using the auxiliary crane 332
Prerequisites 332
6 5 5 Preparations – for installation/removal using the truck crane 333
Prerequisites 333
Special outrigger span 333
6 5 6 Removing/attaching outrigger pads 335
Removing the outrigger pads 335
Attaching the outrigger pads 336
6 5 7 Disconnecting/establishing hydraulic connection 337
6 5 8 Disconnecting/establishing the electrical connection 338
6 5 9 Unscrewing/screwing in the spacers 339
Unscrewing 339
Screwing in 340
6 5 10 Disconnecting/establishing the connections to the supporting box 341
6 5 11 Extending/retracting the outrigger beam 341
Extending the outrigger beam 341
Inserting the outrigger beam 343
6 5 12 Transporting the outrigger beams 345
6 5 13 Note on error messages with removed outrigger beams 346
6 6 Rigging the auxiliary hoist 347
6 6 1 CHECKLIST: Installing the auxiliary hoist 347
Prerequisites 347
6 6 2 CHECKLIST: Removing the auxiliary hoist 349
Prerequisites 349
6 6 3 Slinging the auxiliary hoist 352
6 6 4 Slinging the rigging frame 352
6 6 5 Lowering/raising the rigging frame 353
Prerequisite 353
6 6 6 Placing the auxiliary hoist on the counterweight combination 353
6 6 7 Establishing/disconnecting the hydraulic connection 354
6 6 8 Establishing/disconnecting the electrical connection 355
6 6 9 Making/breaking the connection to the central lubrication 356
6 6 10 Establishing/removing the connection to the turntable 357
Establishing a connection 357
Disconnecting a connection 359
6 6 11 Securing the hoist rope 360
6 6 12 Transporting the auxiliary hoist 361
6 6 13 Checking that the auxiliary hoist is functioning properly 362
Slewing direction 362
Slewing indicator 362
6 6 14 Rigging aid for the hoist rope 363
7 Transportation 365
7 1 Transport with transport vehicle 365
7 1 1 CHECKLIST: Checks before transport 366
7 1 2 Driving the truck crane on to the transport vehicle and lashing down 368
7 2 Transport by ship 371
7 2 1 Additional battery master switch 372
Switching on/off 372
8 Malfunctions in driving mode 373
8 1 Emergency stop switch 373
8 2 Procedure in the event of malfunctions 374
8 2 1 Procedure in the event of a malfunction in road traffic 374
8 2 2 Procedure in the event of engine malfunctions 375
8 2 3 Procedure in the event of transmission malfunctions 376
8 3 Warning and error messages 377
Program version 377
8 3 1 Warning and malfunction messages on the instrument panel 377
Meaning of the lamps 377
8 3 2 Warning and malfunction messages on the on-board computer display 379
Messages 379
Symbols 380
8 3 3 Warning messages on the CCS display 383
Representation of the symbol frame 383
Symbols on the CCS display 384
8 3 4 Engine/transmission error messages 396
Opening the menu 396
Exiting the menu 396
8 4 Troubleshooting 397
8 4 1 Engine malfunctions 397
8 4 2 Faults on the Adblue (DEF) system 399
8 4 3 Malfunctions in the transmission 400
8 4 4 Service brake malfunctions 401
8 4 5 Malfunctions of the steering 402
8 4 6 Differential lock malfunctions 403
8 4 7 Malfunctions in the hydraulic system/hydraulic oil cooler 403
8 4 8 Malfunctions on the suspension 404
8 4 9 Malfunctions of the level adjustment system 404
8 4 10 Malfunction in the CCS control unit 404
8 5 Emergency operation and breakdown assistance 405
8 5 1 Externally starting the truck crane 405
8 5 2 Battery charger 406
Prerequisites 406
8 5 3 Towing the truck crane 407
Important information 407
In the case of engine/transmission damage 407
Tow starting 410
8 5 4 Wheel change 411
Removing a damaged wheel 411
On the spare wheel holder 412
Mounting a wheel 414
8 5 5 Inflating the tyres yourself 415
Connecting the filling hose 415
Inflating the tyres 416
Remove the filling hose 416
8 6 Fuses 417
Notes on changing fuses 417
8 6 1 Fuses in the driver’s cab 418
Group F1 418
Group F2 419
Group F3 419
Group F4 420
Group F6 420
Other fuses 421
8 6 2 Fuses in the battery box 422
Crane operation 423
9 Operating elements for crane operation 423
9 1 Overview of the operating elements 423
9 1 1 Exterior of the truck crane 424
9 1 2 Crane cab 428
Side panel 430
Crane cab, rear 432
Console, rear 434
9 1 3 Control panels 435
Left 435
Right 436
9 1 4 Control lever configuration 437
Version 1 437
Version 2 438
9 1 5 Heating/Air-conditioning system 440
9 1 6 CCS control unit 442
9 1 7 Menu-independent displays 444
9 1 8 CCS – Start menu 445
RCL display 446
Slewing ranges/ working radii display 447
9 1 9 CCS – Overview of menu groups 448
9 1 10 Superstructure menu group 452
Superstructure lock menu 453
Counterweight menu 454
9 1 11 Outrigger/driving menu group 455
Outrigger menu 456
Outrigger cylinders menu 458
Exhaust system menu 460
Air intake inhibitor menu 461
9 1 12 RCL/Telescoping menu group 463
Enter rigging mode/telescope status menu 464
Pre-selection telescoping menu 468
Lifting capacity tables menu 470
Telescoping semi-automation menu 471
Manual telescoping menu 472
9 1 13 Working range limiter menu group 473
Overall height menu 474
Working radius menu 475
Slewing angle menu 476
Hoist rope travel limitation menu 477
9 1 14 Information menu group 1 478
Hydraulic pressure and fuel consumption menu 479
9 1 15 Engine/Additional equipment menu group 480
Remote control menu 481
Spotlights menu 482
Economy menu 483
9 1 16 Telescoping emergency program menu group 484
Telescoping emergency program menu 485
Unknown telescoping menu 486
9 1 17 Settings menu group 487
Crane cab menu 488
Set display brightness and date/time menu 489
Switch units menu 490
Set control lever characteristic curve menu 491
Power unit speeds menu 492
9 1 18 Information menu group 2 493
Operating hours menu 494
Engine/transmission error menu 495
Crane operation error menu 496
Program version menu 497
9 1 19 Various controls 498
9 1 20 Query menus 499
9 1 21 RCL control unit 500
9 1 22 Menu-independent displays 501
9 1 23 RCL – menus 502
Monitoring menu 502
Lifting capacity tables menu 504
Datalogger menu 505
9 1 24 Hand-held control 506
9 1 25 Outrigger control units 507
Menu-independent buttons 507
Outrigger menu 508
Raise axle menu 510
9 2 Short description of the operating elements 511
9 2 1 Definition of direction information 511
Basic rule 511
9 2 2 General rules for buttons and symbols on the display 512
9 2 3 Engine 513
Side panel 513
Economy menu 514
9 2 4 AdBlue (DEF) system/Exhaust gas emission control system 515
CCS display 515
9 2 5 Air intake inhibitor 517
9 2 6 Seat contact switch and dead man’s switch 518
9 2 7 Crane control CCS 519
9 2 8 Outrigger – crane cab 524
Control panels 524
CCS display 525
9 2 9 Outrigger control units 527
General information 527
Outrigger menu 528
9 2 10 Axle raising system 530
9 2 11 Inclination indicators 532
9 2 12 Outrigger pressure displays 533
Outrigger menu 533
Outrigger control units 533
9 2 13 Anemometer displays 533
9 2 14 Counterweight menu 534
Counterweight submenu 534
9 2 15 Main hoist 538
Control panels 538
CCS display 538
9 2 16 Auxiliary hoist 540
Control panels 540
CCS display 541
9 2 17 Slewing gear 542
Control panels 542
CCS display 543
9 2 18 Derricking gear 544
Control panels 544
CCS display 545
Side panel 545
9 2 19 Telescoping mechanism 546
Control panels 546
Display CCS 546
Telescoping semi- automation menu 547
Manual telescoping menu 549
9 2 20 Hydraulic system 552
9 2 21 Superstructure lock menu 553
Turntable lock 553
Houselock 555
9 2 22 Remote control 556
9 2 23 Rated capacity limiter (RCL) 557
CCS display 557
RCL display 566
RCL override – version A 567
RCL override – version B 568
9 2 24 Electrical system 569
9 2 25 Lighting, windscreen wiper/washing system 570
Lighting 570
Windscreen wiper/ washing system 572
Horn 573
9 2 26 Hand-held control 574
Engine control panel 574
Horn 574
Pre-selecting emergency operation 575
9 2 27 Windows and doors 576
Windows 576
Rear window 576
Crane cab door 577
9 2 28 Diagnostics 578
9 2 29 Other 578
10 Starting/switching off the engine – for crane operation 579
10 1 When starting the engine for the first time in the day 579
10 2 Starting the engine – from the crane cab 580
10 2 1 Checking the fuel level and AdBlue (DEF) level 580
Fuel 580
AdBlue (DEF) 580
10 2 2 Checks before starting the engine 582
Checks on the carrier 582
Checking the hand-held control 582
At the hydraulic tank 582
10 2 3 Switching on the ignition 583
10 2 4 Control lever deflection query 584
10 2 5 Display – setting the brightness 585
10 2 6 Starting the engine 585
10 2 7 Checks after starting the engine 586
10 2 8 Setting idling speed 587
10 3 Starting the engine – with the hand-held control 588
Prerequisites 588
Starting the engine 588
10 4 Switching off the engine 589
10 4 1 Normally with the ignition lock / with the hand-held control 589
After switching off 589
10 4 2 Using the emergency stop switches 590
Resetting the emergency stop switch 590
11 Crane operation 591
11 1 Before operating the crane 591
11 1 1 CHECKLIST: Checks before operating the crane 591
11 1 2 Check the condition of the truck crane 595
Crane cab heater fuel tank 595
Visual inspection 595
Checking the position of the hoist ropes 596
Checking the electrical system 597
11 1 3 Adjusting the crane cab seat and front control panel 598
Crane cab seat 598
Control panels 599
Front control panel 599
11 1 4 Checking the safety devices 600
Rated capacity limiter 600
Lifting limit switch 600
Emergency stop switch 601
Seat contact switch 602
11 1 5 Earthing the load 603
11 1 6 Preheating the hydraulic oil 604
Prerequisites 604
Preheating 604
11 1 7 Locking/unlocking the turntable 605
Locking points 605
Locking the turntable 606
Unlocking the turntable 606
11 1 8 Switching the houselock on/off 607
Switching on the houselock 607
Switching off the houselock 609
11 1 9 Setting the time 610
11 2 Standard slewing range type 611
11 2 1 Permissible slewing ranges and operating positions 611
360° slewing range 611
Operating position 0° to the rear 611
180° to the front rigging position 611
11 3 MAXbase slewing range type 613
11 3 1 Specifications in the lifting capacity tables 614
11 3 2 Enabled slewing ranges 615
11 3 3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables 617
11 4 Operation of the rated capacity limiter 619
11 4 1 Switching on the RCL 620
Switching on 620
11 4 2 Entering the rigging mode 622
Notes on Input 622
Enter the slewing range type 623
Entering individual components 624
Entering the RCL code 630
11 4 3 Pre-selecting telescoping 631
11 4 4 Confirming the rigging mode and lifting capacity table 632
Slewing range type Standard 632
MAXbase slewing range type 634
11 4 5 Checks before operating the crane 637
Monitoring menu 637
Checking the rigging mode 637
Hoist checks 640
11 4 6 Displays during crane operation 641
On the RCL display 641
On the CCS display 645
11 4 7 RCL early warning 649
11 4 8 RCL shutdown 649
Shutdown due to overload 649
11 4 9 Displaying the lifting capacity tables 651
Standard slewing range type 651
MAXbase slewing range type 653
11 4 10 RCL override – version A 655
Overview of status display 655
When rigging 656
To raise the boom 657
In emergencies 658
11 4 11 RCL override – version B 659
11 4 12 Data logger 660
Exporting data 660
Displaying the data 661
11 5 Crane operation with main boom 665
11 5 1 Checks during crane operation 665
Horizontal alignment 665
Safe distances 665
Checking the wind speed 666
Deformation of the main boom due to direct sunlight 667
11 5 2 Main hoist 668
Switching on the main hoist 669
Lifting and lowering 670
Maximum permissible hoist rope speed 671
Switching off the main hoist 671
11 5 3 Auxiliary hoist 672
Switching on the auxiliary hoist 672
Lifting and lowering 673
Maximum permissible hoist rope speed 674
Switching off the auxiliary hoist 674
11 5 4 Lifting limit switch and lowering limit switch 675
Lifting limit switch 675
Lowering limit switch 677
11 5 5 Derricking gear 678
Switching on the derricking gear 678
Raising and lowering 679
Maximum derricking speed 680
Re-enabling the raising function 680
Switching off the derricking gear 681
Lowering the main boom to a horizontal position 681
11 5 6 Telescoping mechanism 682
Overview 683
Telescoping process 684
Assignment for display 687
Fixed length, intermediate length, telescoping length 688
Telescoping 689
Telescoping sequence 689
Checks before starting work 690
Switching on the telescoping mechanism 691
Function of the control lever 691
Switching off the telescoping mechanism 694
Manual telescoping 694
Checking the initial position 695
Unlocking the telescoping cylinder 696
Extending/ retracting the telescoping cylinder 698
Lock telescoping cylinder 699
Unlocking the telescopic section 700
Telescoping the telescopic section 701
Locking the telescopic section 702
Before on-road driving 703
Telescoping with semi-automation 704
Telescoping with pre-selection 706
11 5 7 High-speed mode 707
Derricking gear/ telescoping mechanism 707
Hoists 708
11 5 8 Slewing gear 709
Slewing gear brake 709
Switching on the slewing gear 710
Releasing the slewing gear brake 710
Engaging the slewing gear brake 710
Slewing 711
Maximum slewing speed 712
Braking the slewing movement 713
Slewing gear freewheel 713
Switching off the slewing gear 714
11 5 9 Slewing speed – Switching the reduction on and off 715
Switching reduction off 715
11 5 10 Possible movement combinations 716
11 6 Settings and displays for crane operation 717
11 6 1 Inclining the crane cab 717
11 6 2 Setting the idling speed 718
11 6 3 Adjusting the wiper stroke interval of the windscreen wiper 718
11 6 4 Limiting the power unit speeds 719
11 6 5 Setting/switching on Economy mode 720
Automatic 720
Manual 720
11 6 6 Switching the units of measure 721
11 6 7 Setting the characteristic curves for the control levers 722
11 6 8 Using the slewable spotlights 723
Manually swinging 724
Automatic load tracking 724
11 6 9 Overriding torque reduction 725
11 6 10 Cleaning the exhaust system 726
Automatic cleaning 726
Manual cleaning 727
Disabling cleaning 729
11 6 11 Displaying the operating hours 730
11 7 Working range limiter 731
11 7 1 Viewing current settings 732
On the RCL display 732
In the CCS Start menu 733
11 7 2 Opening the working range limiter menu 733
11 7 3 Entering limit values – for the overall height 734
11 7 4 Entering limit values – for the working radius 736
11 7 5 Entering limit values – for the slewing range 738
11 7 6 Entering limit values – for the hoist rope travel 741
11 7 7 Shutdown by working range limiter 743
11 8 Work break 745
11 8 1 In case of short work breaks 745
11 8 2 In case of work breaks longer than 8 hours 746
Securing the truck crane 746
11 9 Heating and air-conditioning system 747
11 9 1 Heating system 747
Switching on 748
Heating 749
Air distribution 750
Manually 751
Automatically 751
11 9 2 UniControl control unit 752
Setting the date and time 753
Saving automatic heating start 754
Error messages 756
11 9 3 Air-conditioning system 757
Notes 757
Switching on 759
Drying the air 759
Switching off 760
11 10 CraneSTAR system 761
11 10 1 Overview 761
11 10 2 Position of the components 761
12 Rigging work 763
12 1 Rigging work checklists for crane operation with the main boom 763
12 1 1 CHECKLIST: Rigging 763
12 1 2 CHECKLIST: Unrigging 767
12 2 Selecting the suitable site 771
12 2 1 Determining the required load-bearing area 771
12 2 2 Safe distance from slopes and pits 774
12 2 3 Earthing the truck crane 775
12 2 4 Safe distance from overhead power lines 776
12 3 Rigging work after driving with a dolly 779
12 3 1 Switching off the boom floating position 779
12 3 2 Switching off the slewing gear freewheel 780
Before slewing 780
12 3 3 Switching off boom pre-tensioning 781
12 4 Connecting/disconnecting the hand-held control 783
12 5 Starting the engine for rigging 785
12 5 1 Starting/turning off the engine with the hand-held control 785
Prerequisites 785
Starting the engine 786
Switching off the engine 786
12 5 2 Starting/switching off the engine from the outrigger control units 787
Prerequisites 787
Starting the engine 787
Switching off the engine 787
12 6 Outriggers – Overview – Standard slewing range type 789
12 6 1 Representation in the lifting capacity tables 789
12 6 2 Enabled outrigger spans 790
12 7 Outriggers – Overview – MAXbase slewing range type 791
12 7 1 Definitions 791
12 7 2 Representation in the lifting capacity tables 793
12 7 3 Enabled outrigger spans 794
12 8 Operating the outriggers 799
12 8 1 CHECKLIST: Extending the outriggers 799
12 8 2 CHECKLIST: Retracting the outriggers 801
12 8 3 Preparing the truck crane 802
12 8 4 Setting the spans 803
For on-road driving 805
12 8 5 Extending/retracting outrigger beams 806
From the control units 807
From the crane cab 808
12 8 6 Moving the outrigger pads into operating/driving position 810
12 8 7 Enlarging the load-bearing area 811
12 8 8 Extending/retracting supporting cylinders 812
From the control units 813
From the crane cab 814
12 8 9 Levelling the truck crane on outriggers horizontally 816
Inclination indicators 816
Prerequisites 817
Manual alignment 818
Automatic alignment 819
12 8 10 Operating the axle raising system 820
12 8 11 Outrigger pressure display 822
12 9 Rigging/unrigging the counterweight 825
12 9 1 Information on rigging 825
When rigging 825
When unrigging 826
12 9 2 Counterweight sections 827
Version 1 827
Version 2 827
12 9 3 Identification 829
12 9 4 Slinging points on the counterweight sections 830
12 9 5 CHECKLIST: Rigging the counterweight 833
12 9 6 CHECKLIST: Unrigging the counterweight 834
12 9 7 Assembling counterweight combinations 835
Version 1 837
Version 2 839
12 9 8 Counterweight hoist unit 841
Counterweight menu 841
Extending/retracting the lifting cylinders 842
Automatic rigging 843
Automatic unrigging 845
Cancelling automatic mode 846
12 9 9 Setting down counterweight for driving the truck crane 847
12 9 10 Slewing with rigged counterweight 850
12 10 Rigging work on the main boom 851
12 10 1 Hook block on the bumper 851
Picking up the hook block 851
Attaching the hook block 852
12 10 2 Hook block in the compartment 853
Prerequisites 853
12 10 3 Hook block on a separate vehicle 855
Picking up the hook block 856
Setting down the hook block 856
12 10 4 Hook block, separable 858
Rigging for on-road driving 858
Rigging for crane operation 859
12 10 5 Reeving and unreeving the hoist rope 860
Reeving the hoist rope 862
Unreeving the hoist rope 865
12 10 6 Possible reeving methods on the main boom 866
With 7 head sheaves 866
With 10 head sheaves 869
With 11 head sheaves 872
12 10 7 Installing/removing the lifting limit switch 873
Installing the lifting limit switch 873
Removing the lifting limit switch 876
12 10 8 Locking/unlocking the lifting limit switch 878
Locking 878
Unlocking 878
12 10 9 Anemometer and air traffic control light 879
Installing 879
Switching on/off 880
Removing 880
For transport 881
12 11 Other rigging work 883
12 11 1 Railings on the turntable 883
12 11 2 Folding the lighting carrier in/out 884
12 11 3 Safety harness on the main boom 885
Prerequisites 886
Requirements 886
Attaching/detaching fall prevention safety system to/ from safety harness 887
Inspecting/replacing the safety harness 889
12 11 4 Slinging points for personal protective equipment 890
12 11 5 Cameras for crane operation 891
Camera on main boom 891
Camera on the hoists 894
Camera on the driver’s cab 894
Operating the camera 895
12 11 6 Step at the crane cab 897
12 11 7 Additional spotlights on the carrier and superstructure 899
On the carrier 899
On the superstructure 900
12 11 8 Slinging points for personal protective equipment 901
13 Driving with a rigged truck crane 903
13 1 Driving route 903
13 2 Permissible rigging modes and axle loads 904
Axle load table 904
13 3 Before driving 907
13 3 1 Secure the superstructure against slewing 907
13 3 2 Checking tyre pressure and wind speed 908
13 3 3 Putting the truck crane on the wheels – with the Raise axle function 909
13 3 4 Putting the truck crane on the wheels – with the outriggers 911
13 3 5 Gears/connections 913
Transmission 913
Switching on separate steering 913
13 4 While driving 915
13 5 After driving 916
14 Malfunctions during crane operation 917
14 1 Emergency stop switch 917
14 2 What to do when malfunctions occur during crane operation 918
The load can be set down 918
Load cannot be set down 918
14 3 Warning and error messages 919
Program version 919
14 3 1 Warning messages on the CCS display 919
14 3 2 Error messages on the CCS display 920
14 3 3 Warning messages on the RCL display 922
14 4 Finding and eliminating malfunctions 929
14 4 1 Engine malfunctions 929
14 4 2 Malfunctions on the main hoist/auxiliary hoist 929
14 4 3 Malfunctions in the hoist cameras 930
14 4 4 Malfunctions in the main boom camera 931
14 4 5 Malfunctions on the derricking gear 932
14 4 6 Malfunctions in the telescoping mechanism 933
14 4 7 Malfunctions on the slewing gear 935
14 4 8 Malfunctions on the counterweight hoist unit 936
14 4 9 Malfunctions in the hydraulic system/hydraulic oil cooler 937
14 4 10 Malfunctions when operating with the hand-held control 937
14 4 11 Malfunctions when inclining the crane cab 937
14 4 12 Malfunctions of the outriggers 938
14 4 13 Malfunctions when raising the axles 938
14 4 14 Malfunctions in the air-conditioning system 939
14 4 15 Malfunctions in the CCS/RCL control units 939
14 4 16 Malfunctions on the CraneSTAR system 939
14 5 Emergency operations and programs 941
14 5 1 Mechanical emergency activation for retracting 942
Prior to the emergency activation, check 942
Procedure 942
Mechanical emergency activation 943
14 5 2 Telescoping emergency program 945
Checks before using the emergency program 945
Open submenu Emergency program 946
Determining the error type 947
In the case of an error at the length indicator 948
Tables for approaching the locking points 952
14 5 3 Entering the current telescoping 955
14 5 4 Emergency operation with the hand-held control 957
Preparations 957
Operating a power unit 958
Stopping movements 960
Stopping movements in emergencies 960
Switching off the engine 960
14 5 5 Notes on slewing in emergency operation 961
For the standard slewing range type 961
For the MAXbase slewing range type 962
14 5 6 Slewing with an overridden slewing gear shutdown 963
14 6 Hydraulic emergency operation with the hand pump 964
14 6 1 Operating principle 964
14 6 2 Switching over the crane’s hydraulic system 965
14 6 3 Establishing the hydraulic circuits required 966
Releasing/ securing valves 966
Switching over valves 967
For lowering 968
14 6 4 Performing emergency activation 969
14 6 5 After the emergency activation 970
14 7 Hydraulic emergency operation 971
14 7 1 Operating principle 971
14 7 2 Establishing the hydraulic circuits required 972
Switching over valves 972
Switching continuous operation on and off 973
14 7 3 Connecting/disconnecting the energy source 974
14 7 4 Carrying out emergency operation 974
14 7 5 After emergency operation 974
14 8 Hydraulic emergency operation as per DGUV 975
14 8 1 DGUV emergency operation operating principle 975
14 8 2 Connecting/disconnecting hoses 976
Establishing connections 976
Disconnecting connections 977
14 8 3 Switching emergency operation on/off 978
14 8 4 Establishing the hydraulic circuits required 979
Switching over valves 979
For lifting/ lowering 981
For slewing 982
14 8 5 Carrying out emergency operation 983
Slewing 983
Derricking 984
Lifting/lowering 984
14 8 6 After emergency operation 985
Switching off emergency operation 985
Switching over to crane operation 985
Disconnecting the hoses 985
14 8 7 Emergency supply of another crane 986
For emergency supply 986
After emergency supply 986
14 9 Fuses in the crane cab 987
Notes on changing fuses 987
Index 993
A 995
B 995
C 996
D 999
E 1000
F 1002
H 1002
I 1004
K 1004
L 1004
M 1005
O 1006
P 1007
R 1007
S 1009
T 1010
W 1012
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