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Manitowoc GROVE GMK, Safety Manual

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5 Maintenance and repairs
5.1 Maintenance

84

3 303 022 en

Safety manual

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4.1

1.

202

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Replace all filters within the specified intervals if cleaning is not explicitly 
permitted. 

Always replace all gaskets before assembly. Clean the sealing surfaces. 

Replace hydraulic hoses immediately once damage or moisture penetration 
becomes visible. 

Make sure that the hydraulic hose lines are replaced at the prescribed intervals 
even if there are no noticeable defects regarding safety.

Escaping hydraulic fluid or compressed air can cause severe injury. Bear in mind 
that the hydraulic and compressed air systems of the truck crane are pressurised 
even when the truck crane is not in operation. Therefore, only tighten loose bolts 
and other connections when the systems are depressurised. Always depressur-
ise the hydraulic and compressed air systems before opening them. 

Make sure to follow the instructions in the maintenance manual relating to 
corrosion protection of the hydraulic cylinders.

Cleanliness is imperative when handling hydraulic oil. Even when topping up with 
fresh hydraulic oil, it must be filtered.

Check fastening and retaining elements (bolts, nuts, lock washers etc.) before 
reusing them and replace them if necessary. 

Observe the information on the torques and on the special torques for your truck 
crane; 

à

Supplied maintenance manual

.

Cleanliness is imperative when handling grease for the central lubrication sys-
tem. Do not remove the caps from the filling hole and grease gun until immedi-
ately before refilling the grease. 

Keep the brake pads and clutch linings free of grease. 

Restore the operational stability of the truck crane once maintenance work is 
completed. Inform the crane operator accordingly. 

The vehicle must meet all applicable current regulations before being put 
into operation and driven on public roads. 

Summary of Contents for GROVE GMK

Page 1: ...3 303 022 en 04 11 2020 Safety manual ...

Page 2: ...rane Group Germany GmbH Industriegelände West D 26389 Wilhelmshaven Germany Phone 49 4421 294 0 Fax 49 4421 294 301 The distribution or duplication of this document as well as the utilisation and disclosure of its contents are prohibited unless explicitly permitted Infringement will incur liability for compensation All rights pertaining to registration of patent or utility model are reserved The o...

Page 3: ... Use a banksman 9 2 5 Hand signals and other signals 10 2 5 1 Horn signals by the crane operator 10 2 5 2 Whistles by the banksman 11 2 5 3 Hand signals by the banksman 11 2 6 Your truck crane 18 2 6 1 Intended use 19 2 6 2 Improper use 20 3 Information on driving 3 1 Before driving 21 3 2 Driving on public roads 24 3 2 1 Driving with trailer 26 3 2 2 Driving with a dolly 26 3 3 Driving on non pub...

Page 4: ... Information on rigging work 41 4 3 1 Load bearing equipment and lifting tackle 41 Safety relevant parts 41 Required checks 41 Only use parts in perfect working order 42 Modification 42 4 3 2 Information on slinging 42 4 3 3 Basic information on rigging 43 Walking on the truck crane 44 Only use the corresponding equipment parts 45 4 3 4 Outrigger 47 4 3 5 Counterweight 48 What to do when rigging t...

Page 5: ...se of danger due to static electricity charge 70 Earthing the load 70 Earthing the truck crane 71 4 7 3 Crane operation in the vicinity of power lines 71 4 7 4 Crane operation with two truck cranes 73 4 7 5 Crane operation in the vicinity of supply lines 74 4 8 Conduct in the event of malfunctions accidents and fire 75 4 8 1 Malfunction in road traffic 75 Information on wheel change 76 Tilting the...

Page 6: ...4 11 2020 5 2 Repairs 85 Information on welding work 85 5 3 Information on electronic components 86 6 Transporting the truck crane 6 1 Loading the truck crane under its own force 87 6 2 Loading the truck crane with another crane 88 ...

Page 7: ...ation on the untended use of your truck crane Information on the improper use of your truck crane General safety instructions Safety instructions for driving truck cranes Safety instructions for rigging and working with truck cranes Safety instructions for operating the crane in special operating conditions Rules of conduct in the event of malfunctions accidents and fire Safety instructions for tr...

Page 8: ... operating conditions further safety precautions may also be necessary Follow all applicable national regulations and laws There may be further safety instructions in terms and conditions of insurance policies company directives etc They must also be observed The manufacturer of the truck crane shall not be held liable in the event of accidents that occur during the use of the truck crane if the u...

Page 9: ... observe them They may include The safe and environmentally sound handling of hazardous substances Wearing personal protective equipment Following road traffic regulations Following all applicable regulations concerning the operation of a truck crane Only trained and qualified personnel may be used to operate the truck crane Only authorised personnel with the required qualifications may perform al...

Page 10: ...and outrigger pressure tables supplied with your truck crane or specially subsequently acquired or provided for the serial number of your truck crane via Manitowoc Crane Care applies to your truck crane All documents supplied with the truck crane are listed on the handover certificate provided All print documents supplied are marked with the serial number of the truck crane on the cover sheet In t...

Page 11: ... e g the minimum age You must be in good physical and mental condition have unrestricted vision and hearing good reaction and coordination skills Have regular medical check ups You must be physically able to handle all the operating elements of the truck crane You must possess a driving licence for this type of vehicle that is valid in the country in which you are working You must have general kno...

Page 12: ...e specific crane operator courses and technical courses You must be able to assess safety risks for yourself and others and act accord ingly You must in particular strive to comply with rules and regulations and follow instructions You must also act in a level headed manner and responsibly under stress and in incidents If a malfunction occurs you must be able to prevent consequential damage Your r...

Page 13: ... the operating elements and moving parts of your truck crane Always wear the required and prescribed person al protective equipment e g helmet hearing pro tection reflective clothing safety boots reflective jacket during work Stay alert Do not operate your truck crane under the influence of alcohol drugs or medication Always keep your eyes on the load or the banks man Only concentrate on your work...

Page 14: ...hat can be walked on You should also clean the driver s cab and the crane cab at regular intervals Do not leave lifting gear chains ropes slings lying around on the deck of the truck crane They pose an increased trip hazard Always stow lifting gear properly that is not needed 2 4 The helpers The helpers are persons outside the crane cab involved in crane operation They include banksmen slingers an...

Page 15: ...not start operat ing the crane until you yourself and your banksman know the meaning of all the signs and signals you use Guidance can be given by whistling using hand signals or walkie talkies Define the responsibilities if more than one person is required as a helper Always only one person may give the required instructions to which you as the crane operator must react Only follow the hand signa...

Page 16: ...r before the crane is used Signal systems not based on hand signals e g walkie talkies must be adequately protected against unauthorised use damage the effects of the weather and all influences that impair the safety of work 2 5 1 Horn signals by the crane operator You can use the horn of your truck crane for communication with the banksman To rule out any confusion horn signals by the crane opera...

Page 17: ...the Stop hand signal for the end of the movement All hand signals must be clearly recognisable even if the banksman is standing at a distance Therefore for some hand signals the banksman must keep his arms next to his body When his arms are held in front of his body the signs are no longer visible from a distance To rule out any confusion hand signals are suggested at this point An overview of han...

Page 18: ... 12 3 303 022 en Safety manual 04 11 2020 Stop all movements halt Upward and downward movement with one arm outstretched at the side Drive back Hand movements with angled arm in direction of travel Move slowly Hold the outstretched hand over the current hand signal ...

Page 19: ...signals Safety manual 3 303 022 en 13 04 11 2020 Move main hoist Place your fist on the helmet After that normal signals Move auxiliary hoist Hold the hand under the angled arm After that normal signals Lift load Circular movements with the hand pointing up s ...

Page 20: ...tions 2 5 Hand signals and other signals 14 3 303 022 en Safety manual 04 11 2020 Lower load Circular movements with the hand pointing down Raise main boom Outstretched arm thumb up Lower main boom Outstretched arm thumb down ...

Page 21: ...al 3 303 022 en 15 04 11 2020 Raise main boom and lower load Signal for raising the main boom in addition wave fingers Lower main boom and lift load Signal for lowering the main boom in addition wave fingers Extend main boom Angled arms thumbs pointing in opposite directions s ...

Page 22: ...gnals and other signals 16 3 303 022 en Safety manual 04 11 2020 Extend main boom sign with one hand Angled arm thumb up Retract main boom Angled arms thumbs pointing at each other Retract main boom sign with one hand Angled arm thumb outwards ...

Page 23: ...y instructions 2 5 Hand signals and other signals Safety manual 3 303 022 en 17 04 11 2020 Slew superstructure Arm stretched out at the side in slewing direction Block all Place one hand on a fist in front of the body ...

Page 24: ...s During loading and unloading work observe the hydraulic oil temperature the shortened maintenance intervals and in the case of the hoists the increased reduction of the theoretical service life à Supplied maintenance manual The truck crane may only be modified with the approval of Manitowoc Crane Group Germany GmbH The manufacturer shall not be liable for malfunctions and damage if the truck cra...

Page 25: ...nual Your truck crane is designed exclusively for lifting loads that are within the per mitted lifting capacities of the truck crane The load must be slung as prescribed to a hook block that is positioned vertically over the load prior to lifting Intended use also includes Observing the entire supplied crane documentation consisting of operating manuals lifting capacity tables outrigger pressure t...

Page 26: ...le walls sheet piles beams etc Two hook operation at the main boom head without additional equipment Two hook operation is carried out in a different way than described in the supplied documentation à Supplied lattice extension operating manual Confirming rigging modes that do not correspond to the actual rigging mode Crane operation with overridden rated capacity limiter or overridden lifting lim...

Page 27: ...ane even if you do not notice any impairment to its operation Electronic components may be damaged by a lightning strike and may fail unexpectedly either immediately or during subsequent operation 3 1 Before driving Only use the access aids provided to climb on and off your truck crane Do not use parts of the crane as access aids Only use the hand grips provided for hold ing Never support yourself...

Page 28: ... outside of the truck crane Check that all covers and safety devices are fitted properly and that they are in good condition Remove any ice and snow from the truck crane à Working with the crane in extreme temperatures p 4 69 Walk around and inspect the truck crane Check for leaking fluids e g oil fuel or water Have leaks repaired professionally and dispose of escaped fluids in compliance with the...

Page 29: ...Remove loose objects from the driver s cab Make sure that no ventilation grids are covered in the driver s cab e g by clothes or bags Check that all operating elements are dry and clean are accessible and have sufficient clearance The pedals must also be clean and dry Remove dirt and moisture from the foot area in order that you do not slip off the pedals Adjust the operator s seat and the rear vi...

Page 30: ...able to react correctly and quickly in case of danger You may only allow the permitted number of persons to ride in the driver s cab on the seats provided for this purpose No one may be transported in the crane cab or anywhere else on your truck crane Before setting off make sure that your truck crane is in a roadworthy driving condition in accordance with the operating manual e g counterweight ho...

Page 31: ...ds or the load bearing capacity of the ground To be able to drive through narrow and low places safely you must know the width and height of your truck crane Always maintain sufficient distance from electric cables and overhead lines While driving also bear in mind that the main boom of your truck crane protrudes forwards beyond the cab and the rear part of your truck crane swings out when corneri...

Page 32: ... be equipped with a slewing gear freewheel and a boom floating position The truck crane can also be equipped with a boom pre tensioning mechanism Before driving always switch on the boom floating position in order that the main boom can move up and down on bumpy ground This prevents the dolly from be ing partially lifted which could cause the permissible axle loads on the truck crane to be exceede...

Page 33: ...clear Drive slowly 3 3 1 Driving from the crane cab This section only applies if your truck crane can be driven from the crane cab Driving from the crane cab is only permitted if the driving distance does not have severely sloping ground Only drive the truck crane from the driver s cab in such conditions Note that the sensing direction on the control levers and the steering angle of the wheels do ...

Page 34: ...ering switched on the truck crane s vehicle handling changes The turning circle of the truck crane will be smaller if you turn the wheels of the front and rear axle lines in the opposite direction The truck crane will move diagonally to the side if you turn the wheels of the front and rear axle lines in the same directions crab travel mode After driving with separate steering switch the truck cran...

Page 35: ... truck crane to avoid the truck crane sinking into the ground when driving You may only drive straight over an obstacle e g a large hump or a step in the ground if you are sure that the underside of the truck crane will not hit the obstacle If the obstacle cannot be driven over straight you must drive over it diagonally You must know when your truck crane is no longer safe on inclines Use all equi...

Page 36: ...the tyre pressure is too low the tyres will be extremely strained and the truck crane could overturn To reduce the risk of overturning you must ex tend the outrigger before driving Extend all outrigger beams to the maximum out rigger span according to the space conditions Extend all outrigger cylinders until the outrigger pads are just above the ground Check the wind speed before and while driving...

Page 37: ...oad if this is explicitly permitted in the lifting capacity table Observe the information in the supplied lifting capacity table and in the supplied operating manual Here you can find the conditions e g position of the super structure telescope status rated capacity limiter setting that you must comply with if you want to drive with a lifted load Driving with a lifted is load is particularly dange...

Page 38: ...rane with chocks so that it cannot roll away Always apply the parking brake after driving Your truck crane cannot be prevented from rolling away by selecting a transmission mode Lock the truck crane to prevent unauthorised use Switch off the engine remove the ignition key and take it If you park your truck crane for long periods of time e g overnight or at the weekend you must also switch off the ...

Page 39: ...st be completed After a lightning strike always have Manitowoc Crane Care check the truck crane before you operate the truck crane even if you do not notice any impairment to its operation Electronic components may be damaged by a lightning strike and may fail unexpectedly either immediately or during subsequent operation 4 1 Choice of a suitable positioning site Work together with the supervisor ...

Page 40: ...f thumb is a 2 x b On natural non loose ground the safe distance a must match the depth of the pit b a rule of thumb is a 1 x b The safe distance is measured from the base of the pit 3 In addition the safe distance c between outrigger pad 1 or substructure 2 and the edge of the slope 4 must always be wider than 2 00 m Check if there are obstacles in the working range If possible choose the site so...

Page 41: ...justing the outrigger cylinders Maximum stroke of the outrigger cylinders à Supplied operating manual The ground must always have sufficient load bearing capacity to be able bear the loads that occur during crane operation If the ground gives way your truck crane may incline or topple over If the load bearing capacity of the ground is not known you can use a table to find out the guide values for ...

Page 42: ...ncrease the support surface by packing the out rigger pads For packing only use suitable materials that will withstand the outrigger pressure e g knotless hardwood of similar cross sections or steel plates with welded on strips that will keep the outrigger pads in position Observe all information on packing à Supplied operating manual Earth the truck crane if required If there is a danger of it be...

Page 43: ...ed lifting capacity table On truck cranes equipped with MAXbase you can also have the lifting capacities for various rigging modes displayed in the crane cab There is an online operations planner for various crane types Scan the QR code shown here or use the address given here http www manitowoccranes com In the Equipment category select the Operations planning area All lifting capacity values giv...

Page 44: ...ts Only use the approved consumables and lubricants for topping up à Supplied maintenance manual Warning tags may have been attached on or in the truck crane Never start the engine if you find a warning tag at any point Wait until it is removed by the person who attached it or by another person who knows more about the reasons Checks on the outside of the truck crane Check that all covers and safe...

Page 45: ...e hoist rope in particular for wear kinks and other damage Replace a damaged or worn hoist rope immediately Description of possible hoist rope damage à Supplied maintenance manual Make sure that the hoist ropes are not entangled or knotted The hoist ropes must lie correctly on the deflection sheaves and be wound on to the hoist drum in accordance with the regulations à Supplied operating manual Re...

Page 46: ...inside outside and above all underneath your truck crane has been completed Sit down on the crane cab seat before starting the engine Only then will you have all operating elements under control and be able to react correctly and quickly in case of danger After switching on the ignition check all operating elements and display elements in the crane cab before you start the engine After starting th...

Page 47: ... operation This can cause loads or parts to fall resulting in serious or fatal injuries Bear in mind that the con sequences of overloading may sometimes occur only after several crane opera tions which can initially lead to a false sense of safety Observe the applicable national regulations for lifting tackle Safety relevant parts Load bearing equipment e g hook blocks and lifting tackle e g stop ...

Page 48: ...d load bearing equipment lifting tackle is not permitted 4 3 2 Information on slinging Determine the weight and if necessary the centre of gravity of the load before slinging the load Bear in mind that the weights of the hook blocks ropes chains crossheads or other lifting tackle need to be added to the weight of the load The lifting capacity of your truck crane must be sufficient to lift the tota...

Page 49: ...tackle or the load does not get caught underneath and thus get stuck Never lift several loads simultaneously even if the lifting capacity of your truck crane would be sufficient to lift the load combination Dangerous situations would be the consequence Check if the load is stuck on the ground or on the base plate support Never try to tear off a stuck load Risk of overturning Do not lift the load u...

Page 50: ... the checklist used before starting a rigging step Otherwise there will be a risk of damage due to requirements not met When unrigging pay attention to the transport condition Always unrig the truck crane to such an extent that it is in proper condition for the subsequent planned transport Bring all equipment parts into the specified transport condition à Supplied operating manual Walking on the t...

Page 51: ...faces equipped with textured surface All points intended for fastening a fall prevention safety system are marked with a symbol The use of a safety harness is generally recommended whenever you walk on the truck crane Only use the corresponding equipment parts Only use equipment parts e g counterweight sections lattice extension MegaWingLift that are marked with the serial number of the truck cran...

Page 52: ...4 Information on crane operation 4 3 Information on rigging work 46 3 303 022 en Safety manual 04 11 2020 Blank page ...

Page 53: ...e area where you intend to extend and retract the outrigger beams Nobody is allowed to be in this area Observe the movements of the outrigger beams and outrigger cylinders when you operate the outrigger or have them observed by a banksman who is in visual contact with you Risk of crushing Compensate for uneven ground with the outrigger cylinders However do not extend one outrigger cylinder signifi...

Page 54: ...tion Observe the rules of conduct in the next section to avoid accidents What to do when rigging the counterweight Rigging the counterweight is a challenging task Only experienced and qualified personnel who are familiar with the valid accident prevention regulations are authorised to sling counterweight sections and guide the crane operator When the engine is running for crane operation the requi...

Page 55: ...nterweight section As the rigging personnel Remove the lifting gear and set down the ends so that the clearance is clearly visible to the crane operator Leave the slewing range of the counterweight and the load As the crane operator Perform the raise hoist movement at the lowest possible speed until the lifting gear is free When unrigging As the crane operator Lift the lifting gear over the counte...

Page 56: ...specified in the supplied lifting capacity table lattice length counterweight combination outrigger span slewing range telescope status Other rigging modes are prohibited Observe the sequence specified in the checklists for rigging work The descrip tion of the individual rigging steps assumes that all the required previous rigging work has already been carried out according to the checklist used O...

Page 57: ...ives the required information on slinging and the weights for the various combinations and transport conditions If there are no fixed slinging points note the specified centres of gravity of the individual lattice extension parts à Supplied lattice extension operating manual Information on rigging If a rigging hook was supplied then connections that are not established with pins are for the most p...

Page 58: ...er support yourself on moving parts e g hydraulic hoses Never reach into bore holes or other confined spaces in order not to crush your fingers or hands Make sure that the lattice extension is secured against swinging before establishing or separat ing the connections During removal make sure that the lattice exten sion is attached to an auxiliary crane with slings before separating the connection...

Page 59: ...coping the main boom with the rigged swing away lattice you must not simulta neously slew the superstructure Slewing pre vents the main boom being exposed to additional side forces and increased swinging and becom ing overloaded Avoid abrupt crane movements to avoid any over load due to swinging loads Bear in mind that switching on high speed modes can also result in abrupt crane movements Various...

Page 60: ...Two hook operation With two hook operation the load is suspended from two hook blocks and is lifted by two independently operating hoists Two hook operation is only permitted for turning over loads as described in the supplied lattice extension operating manual Before turning a load over check that this proce dure is in accordance with the regulations in the country in which you are working Always...

Page 61: ...imiter If the truck crane s current rigging mode is entered correctly the rated capacity limiter will prevent the permissible lifting capacity being exceeded and the truck crane being overloaded It is generally prohibited to operate the crane if the rated capacity limiter is switched off overridden out of service or defective The rated capacity limiter may only be repaired by properly qualified pe...

Page 62: ...a risk that the maximum permissible lifting capacity will be exceeded there is first an early warning and then the crane movements leading into the shutdown range are stopped The rated capacity limiter does not replace safety conscious working Note that even when the rated capacity limiter is switched on the duty of super vision lies with you as the crane operator Never move deliberately into a sh...

Page 63: ...version and depending on country specific settings the rat ed capacity limiter may be overridden in certain cases for rigging or if it is permis sible for leaving the shutdown range Find out about these options in the supplied operating manual and only use the override option for the cases described there 4 4 2 Monitoring the working area Check whether the working area is clear Before every crane ...

Page 64: ...the helpers to stay out of the danger area Helpers must not fasten guide ropes to their bodies under any circumstances as they must be released quickly in case of danger to avoid injury You must never swing the load or the hook block over persons or hold the load there Bear in mind that persons may also be in driver s cabs or similar spaces Always make sure that no one is standing or working under...

Page 65: ...ase If the maximum permissible speeds given in the supplied lifting capacity table are exceeded parts of the truck crane could be overloaded and the truck crane could overturn With long boom lengths even if there is no load on the hook the truck crane could overturn by accelerating or braking the slewing movement too quickly Continuously monitor the horizontal alignment of your truck crane Your tr...

Page 66: ...not be exceeded The values in the lifting capacity table apply to the permissible wind surface of the load If the actual wind surface of your load is larger then the maximum permissible wind speed must be reduced More information on this top ic à Supplied lifting capacity table à Supplied operating manual Check the wind speeds at the anemometer con tinuously during crane operation If the maximum p...

Page 67: ...educe the service life of the main boom Make sure that the maximum permissible values for lateral deformation are not exceeded Risk of accidents Preventive measures If possible turn the superstructure to a park position where both main boom sides are heated evenly to prevent deformation Before any lifting with deformed main boom The main boom must be telescoped out to the length required for the l...

Page 68: ...strained and the truck crane could overturn Depending on the crane type there might not be some lifting capacity tables for the free on wheels working position with which slewing is permitted With these crane types you must put the truck crane on outriggers and then when the su perstructure is in the permissible working position place the truck crane on its wheels The procedure depends on the cran...

Page 69: ...e truck crane into a safe condition in the event of a malfunction Only use an emergency operation or emergency program if troubleshooting using the supplied operating manual leads you to this section or if you are requested to do so by Manitowoc Crane Care Emergency operations and emergency programs are not protected by the rated capacity limiter Extreme care must be taken when performing emergenc...

Page 70: ... where the truck crane is be ing used The radio frequencies can only be changed by Manitowoc Crane Care The remote controls of different cranes cannot be interchanged Make sure that the battery is always charged and have a fully charged spare bat tery ready Otherwise crane operation could be interrupted unexpectedly When operating multiple truck cranes by remote control at the same site take care ...

Page 71: ... less dangerous method of transporting persons is possible In addition to the provisions of in this section always also observe the legal requirements and guidelines for transporting persons applicable in the country in which you are working Further information on transporting persons can be found at the address http fem eur com You can also scan the following QR code In the Product groups categor...

Page 72: ...n is required in the country in which you are working this must be done with the relevant authorities in good time The truck crane must be rigged as prescribed and be level The number of reeved rope lines must be selected such that the load on the hoist rope does not exceed 50 of the rope pull At the same time the total weight of the lifted load must be considered consisting of the weights of the ...

Page 73: ...fting persons is being used and is in a stationary posi tion then the slewing gear hoist derricking gear and telescoping mechanism must be secured against accidental use by being switched off The crane operator is not permitted to leave the crane cab until the equipment for lifting persons has been set down and the person transported has left it Truck crane The truck crane must be equipped in such...

Page 74: ... 8 hours you must also retract and lower the main boom and switch off all current consumers You must secure the truck crane against unauthorised use during every work interruption Switch off the engine remove the ignition key and take it If you do not work with the truck crane for a longer period of time e g overnight switch off the battery master switch and pull off the handle if present If the t...

Page 75: ...the hydraulic oil must be preheated Unrestricted crane op eration is only permitted when the hydraulic oil has reached its required operating temperature à Supplied operating manual Do not touch metal surfaces with damp or wet skin during severe frost as the skin will freeze on immediately Remove any ice and snow from the truck crane before commencing crane operation Keep all handles steps step tr...

Page 76: ...or of the transmitter prior to operation in the effective range of strong high frequency transmitters The earthed truck crane could interfere with transmission Observe all information on how to earth the truck crane and earth the load à Supplied operating manual Earthing the load Even if the truck crane is already earthed à p 4 36 the load may become charged with static electricity For example if ...

Page 77: ...equires special safety precautions Always observe the regulations in the country in which you are working when working in the vicinity of power lines The truck crane is not insulated If parts of the truck crane the load the lifting tackle or the guide ropes touch a power line this will cause serious injury or even death Before starting work ask all persons not to touch your truck crane and the loa...

Page 78: ...suitable locations so that any approach of the truck crane or load to the power line can be seen and reported and to ensure that no person enters the safety area Define the necessary safety precautions for your helpers You yourself are responsible for taking the necessary safety precautions Only use guide ropes made of non conductive material Inform your helpers what to do in the event of contact ...

Page 79: ... cranes The load should not be heavier than 2 3 of the total lifting capacity of both cranes To determine the total lifting capacity the maximum permissible lifting capacities of both truck cranes are added for the current rigging mode according to the lifting capacity table Distribute the load to both cranes according to the lifting capacity This applies particularly if the weight distribution in...

Page 80: ...helpers You yourself and the relevant public utility company are responsible for taking the necessary safety precautions There are frequently supply lines in chemical plants Find out whether special articles of protective clothing are required on the truck crane for use on the company premises e g an air intake inhibitor Always maintain a sufficiently safe distance Always assume that the line is u...

Page 81: ...ncreased risk of accidents for you and the following traffic you should if possible not stop in a tunnel immediately behind a bend or in any other blind spot Secure the truck crane in compliance with the legal regulations applicable in the country in which you are working Switch on the hazard warning system Put on the reflective jacket and if possible reflective clothing before going out on the ro...

Page 82: ... help you change the wheel whenever possible You can use a chain hoist or the truck crane to lift the spare wheel For the precise wheel change procedure observe the information in the sup plied operating manual Retighten the wheel nuts of the mounted wheel after a driving distance of about 50 km and after 150 km Torque à Supplied operating manual à Supplied maintenance manual Tilting the driver s ...

Page 83: ...evice for the driver s cab is loaded in traction or when a fall back guard strut is used Before continuing to drive after the malfunction has been rectified make sure that the driver s cab is lowered to the position for driving and correctly locked Otherwise the driver s cab could overturn when braking 4 8 2 Towing Information on tow starting Tow starting is not possible for reasons related to the...

Page 84: ...ecial breakdown truck or transport ed on a low loading truck Make sure that the braking power of the breakdown truck is sufficient to brake both vehicles and that the compressed air supply of the breakdown truck is sufficient to supply both vehicles The truck crane may only be towed away with a tow rod Using tow ropes is prohibited Attach the tow rod to the front towing coupling Information on the...

Page 85: ... in an emergency as automatic monitoring is no longer available for the most part If you are not sure contact Manitowoc Crane Care After setting down the load get an overview of the displayed warning and error messages and observe the information in the supplied operating manual for further measures If you need to leave the truck crane attach an appropriate warning sign to the crane cab and make s...

Page 86: ...branch of Manitowoc Crane Care in the country in which you are working and specify your crane type and serial number 4 8 5 Fire During operations planning already inform yourself about the fire protection regulations applicable at the site and if necessary equip the truck crane with the required type of fire extinguisher e g CO2 extinguishers Also pay attention to any prescribed number of fire ext...

Page 87: ...g driving and crane operation Some possible consequences of insufficient maintenance are listed here Lack of oil grease and antifreeze Faulty compressed air and hydraulic systems Faulty brakes Faulty tyres or wheel rims Damage to the hoist rope Malfunctions due to dirt 5 1 1 Maintenance intervals Also carry out care and maintenance work carefully within the specified intervals for your own safety ...

Page 88: ... contact Manitowoc Crane Care 5 1 3 Spare parts and consumables Spare parts and consumables must comply with the technical requirements specified by the manufacturer and be approved for your truck crane That is always ensured if you use genuine spare parts and the lubricants recommended by the manufacturer The supplied maintenance manual contains detailed lists of the required spare parts and cons...

Page 89: ...intenance work Lock the crane cab and driver s cab and take the keys Attach warning signs If due to exceptional circumstances the truck crane needs to be put into operation for certain types of maintenance work great care must be taken in the range of moving parts There is a risk of injury The RCL must never be overridden for maintenance work either Enter the current rigging mode at the RCL before...

Page 90: ...d compressed air systems before opening them Make sure to follow the instructions in the maintenance manual relating to corrosion protection of the hydraulic cylinders Cleanliness is imperative when handling hydraulic oil Even when topping up with fresh hydraulic oil it must be filtered Check fastening and retaining elements bolts nuts lock washers etc before reusing them and replace them if neces...

Page 91: ...e spare parts list Repair work also requires appropriate workshop equipment special tools and spare parts approved by Manitowoc Crane Group Germany GmbH Information on welding work All welding work especially on load carrying members may only be performed by properly qualified personnel with the prior permission of Manitowoc Crane Group Germany GmbH Observe the applicable national regulations for ...

Page 92: ...e even if you do not notice any impairment of its operation Electronic components may be damaged by an electric shock and may fail unexpectedly either immediately or during subsequent operation Electronic components are particularly at risk during welding work both due to the extreme heat development and the current flow present during electric welding When cleaning with a high pressure cleaner ma...

Page 93: ... used has sufficient load bearing capacity and a sufficiently large loading area Dimensions and weights of the truck crane à Supplied operating manual Ensure your truck crane is in a safe state before loading it The truck crane must be correctly unrigged and all detachable equipment must be removed or secured against slipping and swinging e g lifting limit switch weight hook block camera 6 1 Loadi...

Page 94: ... operating manual Secure all loose parts on and in your truck crane and secure the truck crane against unauthorised use Lock the crane cab and driver s cab and take the keys After loading check that all folding parts are folded in e g Mirrors railings 6 2 Loading the truck crane with another crane Depending on the type of crane the truck crane may only be lifted at certain parts to avoid damage to...

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