This safety manual is only valid for truck cranes produced by . The safety manual is an integral Manitowoc Crane Group Germany GmbH part of the supplied documentation of your truck crane. You as the crane operator are responsible for the safe operation of your...
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You are therefore responsible yourself for ensur- ing safety and compliance with all laws and requirements. If you have questions on the operation or safety of your truck crane, consult Manitowoc Crane Care 3 303 022 en Safety manual...
2 General safety instructions 2.1 Organisational measures General safety instructions Organisational measures The operating manual(s), the lifting capacity table(s) and the maintenance man- ual must be kept in the truck crane for immediate access at all times, and must not be removed from the truck crane. You must have read and understood the operation and safety instructions in this operating manual and comply with them when working.
Do not modify or retrofit additional units to the truck crane without the approval of if such changes would impair safety. Manitowoc Crane Group Germany GmbH This also applies to the installation of safety devices and to the adjustment of safety devices and safety valves.
2 General safety instructions 2.3 You as the crane operator You as the crane operator The supplied operating manual is not a training manual for prospective crane operators! All descriptions are written explicitly for crane operators who have been trained to operate truck cranes. Personnel in training may only operate the truck crane under supervision.
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Take part in a training course for crane operators if you have no experi- ence with truck cranes. conducts general and type-specific Manitowoc Crane Group Germany GmbH crane operator courses and technical courses. • You must be able to assess safety risks for yourself and others and act accord- ingly.
2 General safety instructions 2.3 You as the crane operator The right working clothes! Always wear the right working clothes! Always use safety gloves made of thick leather when handling ropes and chains. Wear protective gloves if possible for all work outside the crane cab.
2 General safety instructions 2.4 The helpers Inform your replacement! In the event of a change of crane operator, you must inform your replacement about the condition of the crane and all agreements made. Ensure cleanliness and tidiness! The truck crane is your workplace. Keep it clean! Clean your shoes and hands before climbing on to or getting into your truck crane.
2 General safety instructions 2.4 The helpers Ensure the safety of your helpers! Make sure that all helpers are outside the danger area at all times. This applies in particular to persons who secure the load with a guide rope. Use a banksman! The banksman checks the movements of the truck crane and of the load and helps you if you:...
2 General safety instructions 2.5 Hand signals and other signals Hand signals and other signals Hand signals and other signals are suggested in this section. There may be different horn signals, whistles and hand signals, depending on the country in which you are working. Deviations are also permitted. It is important that any deviating hand signals are unmistakable and have been agreed on between the operator and the crane operator before the crane is used.
2 General safety instructions 2.5 Hand signals and other signals 2.5.2 Whistles by the banksman The banksman can communicate with the crane operator by whistling with a signal whistle. To rule out any confusion, whistles for the banksman are suggested in the table: 1 very long whistle Attract attention 1 long whistle...
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2 General safety instructions 2.5 Hand signals and other signals 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.
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2 General safety instructions 2.5 Hand signals and other signals 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. Safety manual 3 303 022 en...
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2 General safety instructions 2.5 Hand signals and other signals Lower load Circular movements with the hand pointing down. Raise main boom Outstretched arm – thumb up. Lower main boom Outstretched arm – thumb down. 3 303 022 en Safety manual...
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2 General safety instructions 2.5 Hand signals and other signals 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.
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2 General safety instructions 2.5 Hand signals and other signals 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 –...
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2 General safety instructions 2.5 Hand signals and other signals Slew superstructure Arm stretched out at the side – in slewing direction. Block all Place one hand on a fist in front of the body. Safety manual 3 303 022 en...
Supplied maintenance manual . The crane produced by is a truck Manitowoc Crane Group Germany GmbH crane! The truck crane was designed and built in accordance with the latest technology and the recognised safety regulations. The laws, regulations, requirements, stipulations and guidelines applicable to truck cranes are complied with.
The truck crane may only be operated with equipment parts that have been approved by and that are labelled with Manitowoc Crane Group Germany GmbH the serial number of the truck crane. Safety manual 3 303 022 en...
2.6 Your truck crane 2.6.2 Improper use shall not be liable for damage resulting Manitowoc Crane Group Germany GmbH from improper or unauthorised use of the truck crane. The user shall bear the full responsibility for any such use. Improper use includes –...
After a lightning strike, always have check the truck crane Manitowoc Crane Care before you drive 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.
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3 Information on driving 3.1 Before driving 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.
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3 Information on driving 3.1 Before driving Check the condition of all tyres and wheel rims. Check the air pressure of all tyres. Tyre pressure à specifications; Supplied maintenance manual . Bear in mind that the air pressure is higher at operating temperature.
3 Information on driving 3.2 Driving on public roads Sit down on the operator's 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 driver's cab before you start the engine! After starting the engine, pay attention to all warning and error messages.
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3 Information on driving 3.2 Driving on public roads While driving, watch out for any warning or error messages. To avoid accidents and damage, you must know what to so when a warning or error message is à issued; Supplied operating manual . Reduce the driving speed in time before sharp bends, narrow places and low headrooms, before ground undulations and especially before tram intersections with trolley-wire cables.
3 Information on driving 3.2 Driving on public roads 3.2.1 Driving with trailer Observe the applicable national regulations for driving with a trailer. Operation with a trailer is only permitted if the truck crane is approved for trailer operation and has been equipped with the appropriate additional equipment (e.g. trailer hitch) by the manufacturer.
3 Information on driving 3.3 Driving on non-public roads Driving on non-public roads You will frequently find unpaved, narrow roads at the site. Depending on applica- tion conditions, also read the sections Off-road driving and Driving with a rigged truck crane . Have someone guide you if possible.
3 Information on driving 3.3 Driving on non-public roads 3.3.2 Driving with separate steering This section only applies if your truck crane is equipped with a separate steering. When the separate steering is switched on, the rear axle lines can be steered independently of the front axle lines.
3 Information on driving 3.3 Driving on non-public roads 3.3.3 Off-road driving You may only drive off-road if these requirements are met: – The main boom is set down on the boom rest. – The superstructure is secured against slewing. –...
3 Information on driving 3.3 Driving on non-public roads 3.3.4 Driving with a rigged truck crane Only drive with rigged truck crane if this is explicitly permitted in the supplied operating manual ! You must know the load-bearing capacity of the route and the truck crane axle loads.
3 Information on driving 3.3 Driving on non-public roads Driving with a lifted load The safety instructions in this section only apply if your truck crane is permitted to drive with a lifted load. When driving with a lifted load, the same safety instructions generally apply as to driving with a rigged truck crane.
3 Information on driving 3.4 After driving After driving Choose the parking space for your truck crane with care! Do not park in places where your truck crane could slip or the ground could be washed away by water. If possible, do not park on a slope. However, if there is no other parking option, secure your truck crane with chocks so that it cannot roll away.
After a lightning strike, always have check the truck crane Manitowoc Crane Care 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 Information on crane operation 4.1 Choice of a suitable positioning site Ensure a safe distance from slopes and pits Set up the truck crane at a safe distance from slopes and pits. The distance also depends on the type of ground if the slopes and pits are not supported.
4 Information on crane operation 4.1 Choice of a suitable positioning site If there are power lines or supply lines (e.g. gas or oil) nearby, then special care is required and you must take special measures. à Crane operation in the vicinity of power lines , p. 4 - 71 à...
4 Information on crane operation 4.1 Choice of a suitable positioning site Check the existing support surface and increase it’s size if necessary Information on the support surface of the supplied outrigger pads; à Supplied operating manual . In case of doubt you must measure the available outrigger pads. If the area of the outrigger pads is smaller than the support surface required for the planned operation, you must increase the support surface by packing the out- rigger pads.
4 Information on crane operation 4.2 Before crane operation and before rigging work Before crane operation and before rigging work 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.
4 Information on crane operation 4.2 Before crane operation and before rigging work Checks before operating the crane Do not assume everything is in working order simply because it was in working order yesterday! Use the appropriate access aids when checking overhead crane parts. Do not use parts of the crane as access aids.
4 Information on crane operation 4.2 Before crane operation and before rigging work Walk around and inspect the truck crane! Check for leaking fluids (e.g. oil, fuel or water). Take appropriate measures. Have leaks repaired professionally and dispose of escaped fluids in compliance with the national and regional regulations.
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4 Information on crane operation 4.2 Before crane operation and before rigging work Make sure that no ventilation grids are covered in the crane cab (e.g. by clothes or bags). Check that all operating elements are dry and clean, are accessible and have sufficient clearance.
4 Information on crane operation 4.3 Information on rigging work Check without load on the hook if all power units are in perfect working order. Observe the required rigging modes for this. Do not start rigging work and crane operation until the hydraulic oil has reached its operating temperature and you have checked all crane functions.
Never use damaged load-bearing equipment/lifting tackle. Damaged load- bearing equipment/lifting tackle must be replaced and marked as not fit for use. If you are concerned about safe use, contact Manitowoc Crane Care Modification Under no circumstances may changes or repairs, e.g. by welding, be carried out on load-bearing equipment/lifting tackle.
4 Information on crane operation 4.3 Information on rigging work Slinging the load must always be done in such a way that it is properly balanced, cannot overturn and cannot fall down. Attach parts only to the designated slinging points. If no slinging points are provided, then ob- serve the centre of gravity specifications.
4 Information on crane operation 4.3 Information on rigging work Support the truck crane on outriggers before slewing the superstructure! The truck crane may only be slewed when not on outriggers if it may be operated free on wheels with a slewing range of 360°. à...
4 Information on crane operation 4.3 Information on rigging work If there is a risk of falling when walking on other surfaces, then suitable equipment should preferably be used that prevents them being walked on (e.g. self-standing ladders, lifting platform, auxiliary crane, rigging hooks). If walking on them is unavoidable, then you must use a suitable safety harness –...
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4 Information on crane operation 4.3 Information on rigging work Blank page 3 303 022 en Safety manual...
4 Information on crane operation 4.3 Information on rigging work 4.3.4 Outrigger The prescribed outrigger span can be found in the lifting capacity table . Only extend the outriggers to the outrigger spans specified in the lifting capacity table for the planned application. Always extend all outrigger beams, even if you are only working on one side.
4 Information on crane operation 4.3 Information on rigging work 4.3.5 Counterweight Observe the lifting capacity table for your truck crane. If your truck crane permits the use of different counterweight combinations, the counterweight sections may only be combined as defined in the lifting capacity table.
4 Information on crane operation 4.3 Information on rigging work When rigging – As the crane operator Lift the counterweight section on to the counterweight platform as described in the operating manual supplied. Now inform the rigging personnel that they may climb on the truck crane. –...
4 Information on crane operation 4.3 Information on rigging work 4.3.6 Lattice extension Your truck crane can be equipped with different lattice extensions. All lattice extensions increase the range and thus the application options of your truck crane. However, they require very special safety precautions, both for rigging and also for crane operation.
4 Information on crane operation 4.3 Information on rigging work Information on slinging To lift the lattice extension parts, only use the approved lifting gear that corresponds to the load. Detailed information on how to sling the available lattice extension is given in the supplied lattice extension operating manual.
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4 Information on crane operation 4.3 Information on rigging work No persons are permitted in the areas ( II ) or ( IV ) during rigging work. There is a risk of fatal crushing injuries here! To reach the connection points on the main boom head, you may only place the ladder/working platform in the safe area ( III ).
MegaWingLift. If you do not have experience in handling truck cranes, then enquire about appropriate training by Manitowoc Crane Group Germany GmbH Information on crane operation When operating the crane with lattice extensions, you must bear in mind that the truck crane reacts more sensitively than usual when braking and accelerating crane movements.
4 Information on crane operation 4.3 Information on rigging work – Information on the required minimum weight of the hook blocks for avoiding slack rope, depending on the system length and the shear rate. – Information on the maximum permissible wind speed during operation and on required measures if it is exceeded.
4 Information on crane operation 4.4 During crane operation During crane operation When lifting a load, compensate for the increase in working radius caused by the bending of the boom by raising the boom, so that the load is lifted vertically and does not drag, injure helpers or topple into the hoist rope (e.g.
4 Information on crane operation 4.4 During crane operation Adjusting the rated capacity limiter correctly Some of the values required for monitoring are automatically acquired and some values will need to be entered by you. The distribution of the val- ues depends on the version of the rated capacity limiter.
4 Information on crane operation 4.4 During crane operation Overriding the rated capacity limiter Always observe all the information in the supplied operating manual before you override the rated capacity limiter. If the truck crane is equipped with a key switch for overriding, then the key may only be inserted for the period of an override.
4 Information on crane operation 4.4 During crane operation Monitor your working area constantly! All persons must be at a safe distance before driving your truck crane, slewing the superstructure or moving the load. Sound the horn when persons approach the working range of your truck crane or the load.
4 Information on crane operation 4.4 During crane operation 4.4.3 Do not overload your truck crane! Pay attention to any unusual noises during crane operation. Accelerate or brake every crane movement slowly. Accelerating or braking too quickly will cause the load to swing. The main boom could buckle or the truck crane could overturn.
4 Information on crane operation 4.4 During crane operation Do not overload the hoist rope! Make sure that no objects hit the loaded hoist rope. That could damage the rope. Always make sure that no slack rope develops during crane operation when the hoist rope is unreeled.
4 Information on crane operation 4.4 During crane operation Sunshine One-sided direct sunshine can lead to a temperature difference between the left and the right main boom sides. This results in a different length extension. A lateral deformation of the main boom is the result. The degree of deformation depends on the actual temperature difference and the current main boom length.
4 Information on crane operation 4.4 During crane operation 4.4.5 Crane operation in the free-on-wheels working position Only work with the truck crane free on wheels (not on outriggers) if this is explicitly permitted in the lifting capacity table! Observe the operating manual and the lifting capacity table . Here you can find the conditions (e.g.
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 emergency operations and emer- gency programs.
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.
4 Information on crane operation 4.5 Transporting persons Transporting persons The truck crane is intended for lifting loads. Transporting persons is considered improper use of the truck crane. It is prohibited to: – Transport persons in any way with the lifting tackle or on the load. –...
4 Information on crane operation 4.5 Transporting persons The prescribed personal protection equipment must be available and used (safety harness, etc.). Personnel Only authorised and properly qualified personnel are permitted to transport persons. The crane operator must comply with the specifications of the manufacturer and the restrictions relating to the lifting accessories (hooks, lifting gear, equipment for lifting persons, etc.).
4 Information on crane operation 4.5 Transporting persons The crane operator is not permitted to exceed the maximum permissible wind speeds and wind loads for transporting persons applicable in the country in which he is working. These values are normally lower than those for lifting loads specified in the lifting capacity table .
4 Information on crane operation 4.6 After crane operation After crane operation 4.6.1 Work break Always set down the load before interrupting work! Never switch off the engine or leave the crane cab as long as a load is suspended. For every work interruption, you must set down the load and switch off the slewing gear.
4 Information on crane operation 4.7 Crane operation under special operating conditions Crane operation under special operating conditions This section is not an operating manual! This section supplements the information in the supplied operating manual . 4.7.1 Working with the crane in extreme temperatures Only operate the truck crane within the approved temperature range;...
4 Information on crane operation 4.7 Crane operation under special operating conditions 4.7.2 Crane operation in case of danger due to static electricity charge The truck crane and load can become charged with static electricity! – Near strong transmitters (radio transmitters, radio stations, etc.). –...
4 Information on crane operation 4.7 Crane operation under special operating conditions Earthing the truck crane The truck crane may in particular become charged with static electricity when using outrigger pads made of synthetic material or when the outrigger pads are packed with insulating material (e.g.
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4 Information on crane operation 4.7 Crane operation under special operating conditions Make sure to have the safety area monitored by one or more banksmen with whom you have visual or radio contact. Concentrate on the signals and signs. The banksmen are to be deployed at 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.
4 Information on crane operation 4.7 Crane operation under special operating conditions 4.7.4 Crane operation with two truck cranes Crane operation with two truck cranes is particularly dangerous! Take special care. If it is necessary to lift a load with two truck cranes at the same time, then the cranes used should have the same properties if possible (truck cranes with telescopic boom).
4 Information on crane operation 4.7 Crane operation under special operating conditions 4.7.5 Crane operation in the vicinity of supply lines Crane operation in the proximity of supply lines (e.g. oil, gas, chemicals) is dangerous and requires special safety precautions! Always observe the regulations in the country in which you are working when working in the vicinity of supply lines.
4 Information on crane operation 4.8 Conduct in the event of malfunctions, accidents and fire Conduct in the event of malfunctions, accidents and fire This section supplements the information in the detailed chapters on malfunctions in the supplied operating manual ! 4.8.1 Malfunction in road traffic In the event of a breakdown or other malfunction, keep calm!
Tilting the driver's cab On some truck cranes of the driver's cab Manitowoc Crane Group Germany GmbH must be tilted to access the engine. Before you tilt the driver's cab, the main boom must be raised sufficiently in order that the driver's cab does not hit the main boom when tilted.
4 Information on crane operation 4.8 Conduct in the event of malfunctions, accidents and fire Before you tilt the driver's cab, you must remove all loose objects in the driver's cab. Depending on the crane type, some special measures still need to be taken à...
. Depending on the type of malfunction, Manitowoc Crane Care the truck crane must be towed away with a special 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.
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...
(e.g. material damage, injuries to persons). In case of an accident, contact the relevant branch of Manitowoc Crane Care the country in which you are working and specify your crane type and serial number.
If locally applicable national regulations require the truck crane to be tested by lifting an excessively heavy load (overload test), always first consult Manitowoc Crane Care Maintenance This section is not a maintenance manual! This section supplements the information in the supplied maintenance manual .
. The training centre at our factory offers specialised training courses for your qualified personnel. For more information 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.
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5 Maintenance and repairs 5.1 Maintenance Observe all warning and information signs on the truck crane. For walking on the truck crane during maintenance work, the same information applies as for walking on it during rigging work. à Supplied operating manual à...
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5 Maintenance and repairs 5.1 Maintenance 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.
– 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 welding (e.g.
After an electric shock (e.g. lightning strike or contact with a power line), always have the truck crane checked by even if you do not notice Manitowoc Crane Care any impairment of its operation. Electronic components may be damaged by an electric shock and may fail unexpectedly, either immediately or during subsequent operation.
6 Transporting the truck crane 6.1 Loading the truck crane under its own force Transporting the truck crane Observe the national regulations that apply to transport when the truck crane needs to be loaded. Also observe the additional safety measures prescribed by the forwarder (e.g.
The lifting gear must be attached in such a way that the truck crane is lifted at its centre of gravity. For more information on how to load your truck crane, consult Manitowoc Crane Care 3 303 022 en Safety manual...