texbooks

Manufacturer’s Specifications
Foreword
1 Safety Instructions
1 Safety Instructions ...........................................................................1
1.1 General ............................................................................................1
1.2 Intended Use ...................................................................................3
1.3 Operating Conditions and Computed Design of the Crane ..............7
1.3.1 General ............................................................................................7
1.3.2 Classification of the Crane...............................................................7
1.3.3 Classification of the Engines ...........................................................9
1.3.4 Workplace Ergonomics .................................................................11
1.3.5 Load and Utilisation of the Crane ...................................................11
1.3.6 Required Ambient Conditions ........................................................13
1.3.7 Service Life ....................................................................................15
1.3.8 Standards and Calculation Regulations .........................................17
1.3.9 Dangers to Air Traffic ....................................................................19
1.4 Safety Regulations ........................................................................21
1.4.1 Organisational Measures ..............................................................23
1.4.2 Selection and Qualifications of Personnel .....................................25
1.4.3 Particular Hazards .........................................................................27
1.4.4 Combination of Hazards with Combined Operation“of
Two or More Cranes ......................................................................39
1.4.5 Driving Operation...........................................................................43
1.4.6 Crane Operation ............................................................................47
1.4.7 Power Supply Failure ....................................................................65
1.4.8 When Assembling and Dismantling Crane Components ...............67
1.5 Hand Signals .................................................................................73
1.5.1 General Hand Signals ...................................................................75
1.5.2 Hand Signals for Working Movements ..........................................77
1.5.3 Hand Signals for Driving Movements ............................................79
2 Overview
2.1 Overview .........................................................................................3
2.2 Safety Signs ....................................................................................5
2.3 Boom System ..................................................................................7
2.3.1 Boom Lengths .................................................................................7
2.4 Serial Plates ....................................................................................9
2.4.1 Serial Plate ......................................................................................9
3 Cab
3.1 Controls in the Crane Operator’s Cab .............................................3
3.2 Instrument Panel Arrangement ........................................................9
3.3 Operation and Function of the Moki (Module Combination) ...........13
3.3.1 Menu Displays ...............................................................................15
3.3.2 Displays and Controls of the Moki (Module Combination) .............17
3.3.3 Main Menu .....................................................................................23
3.4 Pilot control assignment ................................................................33

4 Engine
4 Engine (OM 457 LA) ..................................................................3
4.1 Checks before Starting ..............................................................5
4.2 Starting ......................................................................................7
4.3 Stopping the Engine .................................................................13
4.4 Jump Starting with the Help of a Second Battery ....................13
4.4.1 Jump Starting ..........................................................................15
4.5 Engine Cutout Switch (Optional) .............................................15
4.6 Electronic Engine Management ...............................................17
4.6.1 Engine Control .........................................................................17
4.6.2 Monitoring the Engine ..............................................................21
4.6.2.1 Fault Display ............................................................................21
4.6.2.2 Warnings using Separate Lamps ............................................21
4.7 Cruise Control .........................................................................25
4.8 Temposet (Maximum Speed Setting) ......................................29
5 Driving
5 Driving – General Information ....................................................1
5.1 Axle Loads and Transport Conditions .......................................9
5.2 Driving .....................................................................................13
5.2.1 Starting and Changing Gear ....................................................13
5.2.2 Speed Limitation ......................................................................17
5.2.3 Engine Control / Retarder Brake .............................................17
5.2.4 Cruise Control .........................................................................17
5.2.5 Temposet (Maximum Speed Setting) ......................................21
5.2.6 Stopping and Switching Off the Vehicle ...................................23
5.2.7 Driving over Hill Summits and Driving through
Depressions ............................................................................25
5.2.8 Driving with Axle Loads Over 12 t up to Max. 14.5 t ...............27
5.2.9 Driving on the Construction Site in the Transport
Condition ..................................................................................29
5.3 Driving in Erect Mode ..............................................................31
5.3.1 Driving the Crane without Load ...............................................33
5.3.2 Driving the Crane with Main Boom Extension
(7.6 or 14.0 m) Fitted ...............................................................35
5.3.3 Driving the Crane with Load (Travel Operation) ......................37

6 Transmission
6.1 Operation ...................................................................................3
6.2 Operating Modes .......................................................................5
6.2.1 Automatic Operating Mode ........................................................9
6.2.2 Manual Operating Mode ..........................................................17
6.3 Analysis, Initial Troubleshooting ..............................................27
6.3.1 Emergency Clutch Pedal .........................................................27
6.3.1.1 Using pedal (4) as the emergency clutch ................................27
6.3.2 Emergency Shifting with Emergency Switch (F152) ...............31
6.3.2.1 Emergency Shifting with the Vehicle at a Standstill .................33
6.3.2.2 Changing Gear ........................................................................35
6.3.3 Manual Emergency Shifting on the Transmission ...................37
7 Brakes
7 Braking ......................................................................................3
7.1 Braking System .........................................................................3
7.2 Service Brake ............................................................................5
7.3 Parking Brake ............................................................................5
7.4 Automatic Sustained-Action Brake ............................................9
7.4.1 Engine Control / Sustained-action Brake via Lever (10)............9
7.4.1.1 Engine Brake ...........................................................................11
7.4.1.2 Retarder...................................................................................13
7.4.2 Actuating Lever .......................................................................13
7.4.2.1 Switching on the Sustained-action Brake ................................15
7.5 Anti-lock Brake System (ABS) ................................................17
8 Steering
8 Steering .................................................................................... 1
8.1 General System Description .................................................. ..1
8.2 Safety Instructions .....................................................................3
8.2.1 Safety instructions for protecting the system ............................3
8.2.2 Safety instructions for the protection of life
and limb for maintenance / service work ...................................5
8.3 Monitoring functions for all steering programs ...........................7
8.3.1 Monitoring the steering / emergency steering pump ..................9
8.3.2 Monitoring the electro-hydraulic rear axle steering ..................11
8.4 Steering programs ................................................................. ..13
8.4.1 Selection of the Steering Programme
„Road Travel“ or „Construction Site Operation“....................... 13
8.4.2 Steering program „road travel“ .................................................15
8.4.3 Steering program „construction site mode“ ............................. 19
8.4.4 Synchronising the wheels when changing program ................33
8.5 Steering Computer / Fault Diagnosis / Fault List .....................37
8.5.1 Operating functions ................................................................ .37
8.5.2 Registration of a fault ............................................................... 39
8.5.3 error memory / fault codes...................................................... .43
8.5.4 Fault categories / fault reaction ................................................47
8.5.5 Fault list (following) ................................................................ ..47
8.6 Manual emergency steering .................................................. ..49

9 Differential Locks
9 Differential Locks ........................................................................ 3
10 Hydraulic Suspension
10.1 Suspension Circuits ................................................................... 3
10.2 Level Adjustment ........................................................................ 5
10.3 Monitoring the Level .................................................................... 7
10.4 Locking the Suspension (Travel Operation) ............................... 9
10.4.1 Engaging Procedure ................................................................... 9
10.4.2 Disengaging Procedure ............................................................ 11
10.5 Height Adjustment .................................................................... 11
10.6 Raising the Axles...................................................................... 13
11 Outriggers
11.1 Instructions for Supporting the Crane on the Outriggers ............ 1
11.2 Arrangement of the Outrigger Controls....................................... 3
11.3 Before Extending the Outriggers ................................................ 7
11.4 Procedure for Extending the Outriggers ..................................... 9
11.4.1 Extending the Outriggers
(Support Area 4.8 m x 7.45 m and 6.55 m x 7.45 m) .................. 9
11.4.2 Retracting the Outriggers
... for Driving the Crane in Transport Conditio) ......................... 15
11.4.3 Retracting the Outriggers
... for Driving the Crane in Configured Condition) ..................... 17
11.5 Permissible Ground Pressures ................................................ 19
11.5.1 Safety Distances from Slopes and Ditches .............................. 21
11.6 Support Pressure Display (Optional)........................................ 23
11.6.1 Support force display ................................................................ 25
12 Parking
12 Parking ....................................................................................... 1
12.1 Leaving the Vehicle in Transport Condition ................................ 1
12.2 Leaving the Crane in Configured Condition an with
Outrigger Extended .................................................................... 2
13 Towing the Crane and Towing the Crane to Start
13 Manoeuvring, Tow Starting and Towing ..................................... 1
13.1 Tow Starting ............................................................................... 1
13.2 General Towing Regulations ...................................................... 3
13.2.1 Towing with Engine Damage ...................................................... 7
13.2.2 Towing in the Event of Damage to the Transmission
with the Drive Motor at a Standstill ............................................. 9
13.2.3 Towing with gear damage when the drive motor is running ...... 11
13.2.4 Towing in the event of damage to the distributor gear .............. 11
13.3 Towing the Crane Free on Soft Ground .................................... 13

14 Heating and Ventilation
14.1 Operating the Heating and Ventilation .......................................3
15 Safety Equipment
15 Safety Equipment ......................................................................3
15.1 Electronic Crane Information System (16) ................................3
15.1.1 System Start-up.........................................................................9
15.1.2 Operating and Display Elements .............................................11
15.1.3 Operation of the IC-1 ...............................................................13
15.1.4 Main Menu ...............................................................................15
15.1.5 Setting the operating mode ......................................................51
15.1.6 Load Monitoring Assembly ......................................................55
15.1.7 Bridging the Load Limit Device ................................................57
15.1.7.1 Bridging the Shut-off of the Load Moment Reducing
Movement “Raise Luffing Gear” ..............................................57
15.1.7.2 Bridging the Shut-Down of all Movements ...............................59
15.2 Limit Switches .........................................................................61
15.2.1 Bridging the Hoist Limit Switch ................................................61
15.2.2 Lower Limit Switch ...................................................................61
16 Notes on Operation
16.1 Permitted Wind Speeds .............................................................1
16.2 Wind Speed and Dynamic Pressure .........................................3
16.2.1 Crane in the Wind with Load ......................................................3
16.3 General Notes on Operation......................................................7
16.4 Raising a Load Using Several Cranes ......................................9
16.5 Checking the Safety Measures ...............................................11
16.6 Operating Information on Pilot Control .....................................13
17 Slewing
17.1 Preparations for Slewing ...........................................................3
17.2 Slewing the Superstructure .......................................................5
17.3 Slew Speeds .............................................................................7
17.4 Braking the Superstructure........................................................9

18 Telescoping
18 Telescoping ...............................................................................3
18.1 General ......................................................................................3
18.2 Locking and Pinning Unit ...........................................................5
18.2.1 Locking and Pinning Unit (LPU) in the Position
„Driving on the Road“ ............................................................... 9
18.3 Controls ...................................................................................11
18.4 Telescoping Information System .............................................11
18.4.1 General ....................................................................................11
18.4.2 Telescoping Display ................................................................13
18.4.3 Automatic Operation ................................................................17
18.4.4 Entry of the Length Code - Selection of the
Main boom Length ...................................................................19
18.4.5 „Tele Manual“ - Display ...........................................................21
18.4.6 Manual Telescoping .................................................................25
18.4.7 Teaching the Extension Sequence of the
Telescopic Sections ................................................................29
18.5 Extension Lengths of the Telescopic Sections........................31
18.5.1 Checking the Extension Lengths During the
Telescoping Procedure ...........................................................33
18.5.2 Extension Sequence of the Telescopic Sections ....................33
18.6 Lifting Capacities in the Unpinned Condition ...........................35
18.6.1 Load Capacities in Intermediate Positions ...............................35
18.6.2 Telescopable Load Capacities ................................................37
18.1 Telescoping Lifting Capacities
19 Luffing
19.1 Raising and Lowering the Main Boom .......................................3
19.2 Raising the Main Boom in High Range ......................................5
19.3 Luffing Speeds ...........................................................................5
19.4 Luffing Cylinder - Monitoring the Pressure Difference
with Special National Regulations .............................................7
20 "Hoist" Hook Operation
20.1 Raising and Lowering the Load with Hoist 1 ..............................3
20.2 Hoist Speeds .............................................................................5
20.a Hoist 2
20.a Hoist 2 (Optional) .......................................................................3
20.a.1 Fitting and Removing Hoist 2 .....................................................3
20.a.1.1 Fitting .........................................................................................3
20.a.1.2 Removal ....................................................................................5
20.a.2 Additional Folding Sheave for Hoist 2 (Optional) .......................7
20.a.3 Raising and Lowering the Load Using Hoist 2
(Optional) ...................................................................................9
20.a.4 Hoist Speeds ...........................................................................11

21 Main Boom Extension
21.1 Fitting the Main Boom Extension ...............................................3
21.2 Folding the Main Boom Extension .............................................3
21.2.1 Folding the 7.6 m Basic Boom out of the Transport
Position into Operating Position 0o ............................................................................. 5
21.2.2 Folding the 14 m Main Boom Extension from the Transport
Position into Operating Position 0o .......................................................................... 13
21.2.3 Folding the Main Boom Extension ( 7.6 m or 14 m) from 0o
into the 20o or 40o Operating Position ......................................19
21.3 Fitting Procedure .....................................................................23
21.4 Operation with Main Boom Extension......................................25
21.5 Boom Point (Hall Point, Option) ...............................................27
21.5.1 Lift loads with a main boom angle of 35-45o
(medium length boom point).....................................................27
21.5.2 Lift loads with a main boom angle of less than 35o
(short boom point) (or 25o for simultaneous use of
the load hook) ..........................................................................29
21.5.3 Lift loads with a main boom angle of greater than 45-70o
(long boom point) .....................................................................29
21.5.4 Lifting loads ..............................................................................31
21.5.5 Boom Point in the Transport Condition ....................................31
21.6 Hook (15t) for boom point (Option) ..........................................33
21.7 Searcher Hook (Option) ..........................................................35
21.7.1 Operating with the Searcher Hook ..........................................35
21.8 Angling the 8th Boom Section ..................................................39
22 Reeving
22.1 Rope Equipment and Reeving ...................................................3
22.1.1 Uneven-numbered reeving ........................................................5
22.1.2 Even-numbered reeving ............................................................5
22.2 Load Lifting Equipment ..............................................................7
22.2.1 Hoist ropes ................................................................................9
22.2.1.1 General ......................................................................................9
22.2.1.2 Rope End Connections .............................................................9
22.2.2 Hook Blocks ............................................................................13
22.2.2.1 Definition ..................................................................................13
22.2.2.2 Markings ..................................................................................13
22.2.2.3 Handling...................................................................................15
22.3 Reeving the Hoist Rope on the Main Boom Head ...................19

23 Counterweight
23 Counterweight 10.0 t .................................................................... 3
23.1 Dismantling the 0.48t and 1.1t Counterweight Blocks ................. 3
34 Radio System
34.1 Radio-remote Control of the Crane (Optional) ............................. 1
34.2 Safety Regulations ...................................................................... 3
34.3 Important Information before Operating the Radio System .......... 3
34.4 Radio Receiver ............................................................................ 5
34.5 Indicator Light Field of the Radio Receiver .................................. 5
34.6 Control Elements of the Radio Transmitter .................................. 7
34.7 Display Screens During Crane Operation ................................... 9
34.8 Safety Instructions for Operation ............................................... 11
34.9 Safety Instructions for the Battery and Charge Unit .................. 15
34.10 Servicing .................................................................................... 15
36 Emergency activation
36 Emergency activation (optional) ................................................3