3 112 254 en 20110330 PDF

Safety Manual
3 112 254 en
30.03.2011
Importante note
Any type of duplication or excerpt from this docu-

ment, also in electronic form, is not subject to the
revision service of
Manitowoc Crane Group Germany GmbH.
© Copyright reserved by
Manitowoc Crane Group Germany GmbH

Industriegelände West
D-26389 Wilhelmshaven, Germany
Tel: [+49] (0)44 21 294-0
30.03.2011
Fax: +[49] (0) 44 21 294-301

The passing on or duplication of this document as well as the utilisation and disclosure of its contnets are prohibited unless
expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patente or uti-
lity model are reserved. The original language of this document is German.
3 112 254 en Safety Manual

1 About this safety manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
2 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
3 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

3.1 The truck crane as a vehicle and a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
3.2 You as the crane operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
3.3 Helpers (banksmen, slingers, guides for holding ropes). . . . . . . . . . . . . . . . . . . 1 - 10
3.4 Signals and hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Horn signals by the crane operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Whistling signals by the banksman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Hand signs by the banksman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
4 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23
4.1 Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23
4.2 While driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 25
On-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 26
Driving on the site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 27
Off-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 28
Driving with a rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 29
Driving with a load on the hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 30
Driving from the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 31
Driving with all-wheel steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 31
Driving with a trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 32
4.3 After driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 32
5 Crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 33
5.1 Before crane work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 33
5.2 Rigging lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 39
5.3 During crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 43
Crane operation with a lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 49
Two-hook operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 51
Working with a free-standing truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 51
Working with attached solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 52
Working with two cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 52
5.4 After crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 53
Work break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 53
Unrigging the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 53
6 Crane operation under special operating conditions. . . . . . . . . . . . . . . . . . . . . . . 1 - 55
6.1 During the winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 55
6.2 Working near electric cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 56
6.3 Working near strong high-frequency transmitters or in potentially
stormy weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 57
6.4 Working near supply lines (e.g. oil or gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 58
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Safety Manual 3 112 254 en 1-1
7 Proper conduct in the event of malfunctions, accidents and fires . . . . . . . . . . . 1 - 59
Fuse change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 59
7.1 Breakdown in road traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 59
Tyre change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 60
Tilting the driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 60
7.2 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 61
Towing away. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 61
Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 61
7.3 Crane operation malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 62
7.4 Accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 62
7.5 Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 62
8 Transporting the truck crane on a separate vehicle. . . . . . . . . . . . . . . . . . . . . . . 1 - 63
8.1 Loading the truck crane yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 63
8.2 Loading the truck crane with another crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 64
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1-2 3 112 254 en Safety Manual

1 About this safety manual

This safety manual only applies to truck cranes constructed by Manitowoc
Crane Group Germany GmbH. The safety manual is part of the documentation
supplied with your truck crane.
As a truck crane operator you are responsible for the safe operation of your
truck crane.
This safety manual is intended to warn you of the hazards that may occur
during the daily operation of your truck crane and show you how to avoid
these hazards from the onset or react appropriately should they occur.
The safety manual contains:
– Information about the proper use of your truck crane.

– General safety instructions.
– Safety instructions that apply to truck crane driving.
– Safety instructions for rigging and working with truck cranes.
– Safety instructions for crane operation under specific operating condi-
tions.
– Instructions concerning proper conduct in the event of malfunctions, ac-
cidents and fires.
– Safety instructions concerning truck crane transport with another vehicle.
The crane operator is obliged to read the safety manual carefully, as this is
essential for the safe operation of the truck crane.
Keep the manual in a place that is handy so that it is easily accessible when-
ever you need to reread certain sections.
The instructions and measures contained in this safety manual will not
protect you from all hazards that may occur when working with the truck
crane.
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The safety manual contains only general safety instructions and basic safety
measures. They supplement the safety instructions and precautionary
measures that are contained in the operating manual and other documen-
tation supplied with your truck crane (lifting capacity and outrigger pressure
tables, maintenance manual) and displayed on warning and information signs
on and in your truck crane. You must observe these safety instructions and
precautionary measures as well as those contained in this safety manual.
Special operating conditions may also require additional safety measures.
Always observe the laws and regulations of

the country in which you are working.
Additional safety instructions may be speci-
fied in the terms and conditions of insurance
policies, company policy, etc. These instruc-
tions must also be observed.
The truck crane manufacturer is not liable for

accidents caused during the operation of the
truck crane if the user has not complied with
the laws, regulations and requirements that
apply to mobile boom cranes.
The manufacturer has no direct influence on

the way you use, operate or maintain your
truck crane. You are therefore responsible for
ensuring the safe operation of the crane and
the fulfilment of all laws and regulations.
If you have questions on the operation or safety of your truck crane, contact
Manitowoc Crane Care.
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2 Proper use
2 Proper use
Your truck crane was built in accordance with the state of the art and the rec-
ognized safety regulations valid at the time of commissioning. Neverthe-
less, personal injury to the operator or a third party as well as damage to the
crane and other property may occur during use.
Your truck crane may only be modified with the consent of the manufactur-
er.
Your truck crane must be in proper working order and may only be used for
its intended purpose, while taking into account the safe operation of the unit
and any related hazards.
Malfunctions that may affect the safe operation of the unit are to be correct-
ed immediately.
Your truck crane may only be operated at temperatures of between –25 and
+40 °C if it is not equipped with the proper special equipment.
Your truck crane may only be used as an erection crane to vertically lift
loads in the authorized rigging modes using a hook block that is reeved to
the hoist rope. The weight and centre of distribution of the loads must be
known. Any other use of the crane is considered improper.
The manufacturer is not liable for damage resulting from the improper or
unauthorized use of the truck crane. The user shall take on full responsibility
for any such use.
Proper use also includes:
– Observation of the complete crane documentation, consisting of the op-

erating instructions, the lifting capacity table, the outrigger pressure table
and the safety manual.
– Following of the inspection and maintenance requirements according to
the maintenance manual.
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2 Proper use
Improper use includes:
– Transporting loads on the carrier.

– Pushing, pulling or lifting loads with the level adjustment system, the
beams or the outrigger cylinders.
– Pushing, pulling or lifting loads off of the ground using the slewing gear,
the derricking gear or the telescoping gear.
– Pulling off fixed objects using the crane.
– Two-hook operation.
– Free-standing operation outside the authorized slewing range.
– Defining RCL codes that do not correspond to the actual rigging mode.
– Working with an overridden RCL.
– On-road driving in an unauthorized driving mode (axle load, dimension).
– Moving the rigged crane in an unauthorized driving mode.
– Use of equipment that is not authorized for use with the crane.
– Transportation of people with unauthorized means of passenger trans-
portation.
– Carrying passengers outside of the driver's cab.
– Loading and unloading work, i.e. continuous operation without a cor-
responding break.
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3 General Safety Instructions

Always use extreme caution when operating the truck crane.
Keep in mind that accidents could cause injury or death or significant dam-
age to property. Safety-conscious operation protects not only you but also
those around you.
You are personally responsible for safety.

It is your job to read the documentation of
your truck crane (operating manual, lifting cap-
acity table, outrigger pressure table, maintenance
manual) completely and carefully and ensure
that you understand its contents.
Read the warning and information signs on

and in the truck crane with the same care and
follow their instructions.
Ensure that the signs remain legible and re-
place any missing or damaged signs immedi-
ately.
Always keep the operating manual and the lifting capacity table in the truck
crane. This documentation is to accompany you through every working day.
The manufacturer is not liable for malfunctions and damage arising from
the non-observance of the commissioning, operating and maintenance in-
structions contained in this documentation.
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3.1 The truck crane as a vehicle and a crane
A new truck crane must be run in during the first few hours of operation.
The run-in regulations for your truck crane may be found in the maintenance
manual.
Your Manitowoc Crane Group Germany GmbH truck crane is an erection crane.
The truck crane was designed and manufactured as an erection crane in
accordance with the state of the art and the applicable technological stand-
ards. The laws, regulations, requirements and guidelines that apply to mo-
bile boom cranes have been observed. The truck crane is not designed for
loading and unloading work (continuous operation without corresponding
breaks). Monitor the temperature of the hydraulic oil and note the shorter
maintenance intervals (refer to Maintenance Manual) for loading and unload-
ing work.
Only operate the truck crane at permissible outdoor temperatures.

Without special equipment, the truck crane may only be operated in outside
temperatures of –25 °C to +40 °C. The truck crane may only be operated at
temperatures outside of this range if it is equipped with this special equip-
ment.
You must know the lifting capacity of your crane under the respective oper-
ating conditions.
You may not begin crane work unless your truck crane disposes of the
required lifting capacity. Further information may be found in the lifting
capacity table.
Your truck crane must be roadworthy and in good working order.

If you are unsure of the operational safety and roadworthiness of your truck
crane, you must stop driving or discontinue crane work immediately.
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All maintenance and repair work must be

completed before starting up the truck crane.
Carry out the prescribed inspections daily be-

fore starting up the truck crane. Further infor-
mation may be found in the operating
instructions.
Observe the prescribed maintenance inter-

vals. All maintenance work must be carried
out professionally. Further information may
be found in the maintenance manual.
Never put off necessary repair work. All repair work must be carried out im-
mediately by trained, qualified personnel.
Only original manufacturer replacement parts may be used if any parts

need replacing. Further information may be found in the spare parts list.
Always keep your truck crane clean. This applies in particular to the warning
and information signs, operating and control instruments, mirrors, win-
dows and other glass surfaces. Keep all accessible surfaces free of dirt, oil
and grease. Clean your shoes and wash your hands before climbing onto or
getting into your truck crane.
Always use the mounting brackets on your truck crane that are provided for
the specific piece of equipment (e.g. wheel chocks, ladders). Keep all tools
in the tool-box. Secure all loose articles.
The truck crane may only be modified with the manufacturer's express
consent.
The manufacturer is not liable for malfunctions and damage if the truck
crane is modified or re-equipped without our consent, especially if the effec-
tiveness of built-in safety devices is deliberately reduced or eliminated.
Any welding work on load carrying members of the truck crane may only be
carried out with the manufacturer's express consent.
Observe all applicable regulations of the country in which you are working
(e. g. rules for the prevention of accidents or rules for fire prevention).
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3.2 You as the crane operator
If you drive or work with a truck crane, you must fulfil the following funda-
mental requirements:
• You must possess the prescribed authoriza-

tion certificate and carry it with you at all
times.
• You must have read and understood the
documentation of your truck crane and all
warning and information signs in and on
your truck crane.
• You must know and understand the signals
and hand signals used to communicate with
banksmen, slingers and others.
• You must be in good mental and physical
condition, have excellent vision and hearing
and good coordination. Have regular physi-
cal examinations.
• You must be physically able to operate all operating element on the truck
crane.
• You must have mastered all operating procedures and be able to operate
all safety devices. Furthermore, profound knowledge of the truck crane's
behaviour is essential. Familiarize yourself with the truck crane, its oper-
ation and special features before initial use. Take a training course for
crane operators if you have no previous experience with truck cranes.
• You must be able to foresee possible safety risks and act accordingly. In
particular, you must strive to observe all rules and regulations and follow
all instructions.
• You must keep calm and act in a responsible manner even if you are un-
der stress or incidents occur. If a malfunction occurs, you must try to pre-
vent consequential damage.
• If an accident occurs, you must be able to give first aid and know where
to find additional help.
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• In the event of a fire, you must know how to use the appropriate aids and
a fire extinguisher and know where to find additional help.
Always wear appropriate working clothes.
Wear close-fitting clothes. Avoid open jackets
and shirt sleeves, loose scarves, rings, chains
and other objects that may catch on the oper-
ating elements and movable parts of your
truck crane.
Wear the prescribed articles of protective

clothing (e.g. hard hat, reflective clothing and
safety boots) when working with the crane.
When working with ropes and chains, always

wear safety gloves made of thick leather. Also
wear safety gloves when working outside the
crane cab.
Stay alert.
Never work with your truck crane when under the influence of drugs, alco-
hol or medication.
Keep your eyes on the load or the banksman.

Concentrate on your work and do not let any-
thing distract you. Do not read, drink, eat or
smoke during crane work.
Stop working when you feel tired and can no

longer guarantee the safe operation of your
truck crane.
Notify your relief operator.

You must inform your relief of the condition of
the crane and any agreements that have been
made when handing over the crane to the new
operator.
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3.3 Helpers (banksmen, slingers, guides for holding ropes)
You are responsible for the safety of your helpers.

Employ trained, qualified and experienced helpers, e.g. as banksmen, slin-
gers and holding rope guides. Give your helpers careful instruction.
Use a banksman.
The banksman monitors the movements of the truck crane and the load and
helps you when you:
– Cannot see the entire working area.
– Cannot see the load at all times or cannot see it well enough.
Agree on the signals that you and your banksman will use. Do not begin
crane work until you and your banksman understand all of the signs and sig-
nals that you intend to use. The banksman may guide you using whistling
signals, hand signs or a walkie-talkie.
Watch only the hand signs and signals used by your banksman, but always
heed stop signals, even those used by others.
Stop work immediately if you can no longer see your banksman or have lost
contact to him.
When operating the crane at night, ensure that your banksman is standing
in a well-illuminated area so that you can see him clearly at all times.
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1 - 10 3 112 254 en Safety Manual

3.4 Signals and hand signals
Signal systems that are not based on hand

signs (e.g. walkie-talkies) must be sufficiently
protected against unauthorized use, damage,
weathering and all other conditions that may
impair operational safety.
Horn signals by You may use the horn of your truck crane to communicate with your banks-
the crane operator man. The following horn signals are recommended in order to prevent mis-
understandings:
I understood your signal: 1 short blast

(also: I will follow your signal)
Repeat your signal: 2 short blasts
(also: give me signals)
I cannot follow your signal: Continuous blast
(also: I have a malfunction)
Be careful, you are in danger: Long blasts with short pauses
Whistling signals The banksman may communicate with the crane operator by blowing a sig-
by the banksman nal whistle. The following whistle signals are recommended in order to pre-
vent misunderstandings:
To get attention: 1 very long blow

Stop movement: 1 long blow
Raise a load: 2 short blows – pause – 2 short
blows
Lower a load: 3 short blows – pause – 3 short
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blows
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Safety Manual 3 112 254 en 1 - 11
Hand signs by the The banksman and crane operator may also communicate using hand sig-
banksman nals.
The banksman uses an appropriate hand signal to indicate the movement
that is to be performed with the truck crane. The crane operator performs
the respective movement until the banksman uses the hand sign Stop to in-
dicate the end of the movement.
All hand signs must be clear and recognizable, even if the banksman is
standing far away. The banksman must therefore keep his arms beside his
body for some hand signals. If he holds his arms in front of his body, the
signs will not be distinguishable at greater distances.
The following hand signs are recommended in order to prevent misunder-
standings:
Hand signals for driving with the truck crane

The banksman stands in front of the truck crane.
Drive to the right

Movement to the side with the bent arm.
Drive to the left

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Drive backwards
Hand movements with the bent arm.
Drive forward and show distance

If necessary, show distance with both hands.
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Hand signals for driving with the truck crane

The banksman stands behind the truck crane.
As the driver, make sure that you see the banksman laterally reversed in the
rear vision mirror.
Drive to the right

Drive to the left

Drive forward
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Drive backwards and show distance

If necessary, show distance with both hands.
Hand signals for crane operation

The banksman is within the crane operator's field of vision.
Stop movement
Stretch both arms out to the side.
Stop movement when danger is present

Up-and-down movements with both arms
stretched out to the side.
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Move the main hoist

Place fist on helmet, then normal signals.
Move auxiliary hoist

Place hand under the bent arm, then normal
signals.
Raise a load
Circular movements with hand pointing up-
wards.
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Raise load slowly

Circular movements with hand pointing up-
wards, holding the other hand stretched out
above it.
Lower a load
Circular movements with hand pointing
downwards.
Lower load slowly

Circular movements with hand pointing
downwards, holding the other hand stretched
out below it.
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Raise the main boom

Upward movements with arm stretched out.
Raise the main boom slowly

Circular movements with arm pointing up-
above it.
Lower the main boom

Downward movements with arm stretched
out.
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Slowly lower the main boom

Downward movements with arm pointing up-
below it.
Raise main boom and lower load

Upwards movements with arm stretched out,
at the same time circular movements with the
other hand stretched out downwards.
Lower the boom and raise the load

Downwards movements with arm stretched
out, at the same time circular movements with
the other hand stretched out upwards.
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Raise main boom and hold load

Upward movements with stretched out arm,
put other hand together with fist.
Lower main boom and hold load

Downward movements with stretched out
arm, put other hand together with fist.
Extend main boom telescoping

Movement to the side with both bent arms.
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Retract main boom

Movement to the side with both bent arms.
Raise the luffing jib

Upward movements with stretched out arm,
stretch out other arm upwards.
Lower the luffing jib

Downward movements with stretched out
arm, stretch out other arm upwards.
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Turn the superstructure to the left

Stretch out arm to side.
Turn the superstructure to the right

Stretch out arm to side.
End work
Put both hands together above head.
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4 Driving
4 Driving
The following safety instructions and precautionary measures for driving
supplement the safety instructions and precautionary measures contained
in the operating manual.
4.1 Before driving
Ensure that none of the vent grilles in the driver's cab are covered (e.g. by
pieces of clothing or bags).
Use only the steps and ladders when getting on and off your truck crane.
Use only the handles provided to keep a firm hold. Never hold onto control
levers, hoses or cables. Always make sure you have a solid foot-hold and
firm grip, particularly in wet conditions. Never jump from your truck crane
unless it is an emergency.
Never reach into movable components unless these are securely locked
against each other and the engines of both the vehicle and the crane are
shut off.
Inspect your truck crane. Walk around the truck crane before beginning to
drive.
Do not assume that everything is in working order simply because it was in
working order when work was last completed.
Check that all necessary safety devices (e.g. guards, covers and lighting) are
properly secured and in good working order.
Ensure that no fluids (e.g. oil, fuel or water)

have leaked or are leaking. Seal the leak and
dispose of the leaked material accordingly.
If nuts or bolts have loosened, tighten the

screw connection again and replace missing
parts. Use only the original spare parts provid-
ed by the manufacturer.
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30.03.2011

4 Driving
Check the level of the fuel, engine oil, coolant, hydraulic oil and all other
consumables and lubricants. Only authorized consumables and lubricants
may be used for refilling.
Ensure that the seals, e.g. filler-necks and outlet sleeves, on all systems are
in place and secured properly.
Check the condition of all tyres and wheel

rims. Check the air pressure in all tyres. Details
concerning the tyre pressure may be found in
the operating manual and the maintenance
manual. Keep in mind that the air pressure in
warm tyres is higher.
Exhaust fumes are deadly! Ensure that you

have sufficient ventilation if you must start the
engine in a closed-in area.
Warning tags may be located in or on the truck

crane.
Never start the engine if you find one of these
tags anywhere. Wait until the warning sign is
removed by either the person who put it there
or someone who knows why it was put there.
Check all operating elements before starting

the engine.
Ensure that all operating elements are clean,
dry, accessible and operable. Remove any
loose objects from the cab floor.
All operating elements that may cause the inadvertent movement of the
truck crane when the engine is started must be in zero position. All pedals
must be clean and dry. Keep the cab floor free of dirt and moisture to pre-
vent your feet from slipping off the pedals.
30.03.2011

4 Driving
Adjust the driver's seat and the rear vision mirror accordingly.
Do not start the engine until you are sure that all preparatory work inside,
outside and in particular under the truck crane has been completed.
You may only start the engine when sitting on the driver's seat. This is the
only position from which you have control of all operating elements and can
quickly and properly react to potential danger.
Monitor all warning and indicator lamps as well as the control instruments
when the engine is started.
Further information may be found in the operating instructions.
4.2 While driving
Drive carefully and do not endanger the lives of others or cause damage to
property.
Only start the engine when sitting on the driver's seat. This is the only posi-
tion from which you have control of all operating elements and can quickly
and properly react to potential danger.
You may only take the permitted number of passengers on the seats provid-
ed in the driver's cab. No one is permitted to ride in the crane cab or any-
where else on your truck crane.
Activate the warning devices required by the regulations of the country in

which you are working (e.g. headlights, rotating beacons).
Begin driving slowly. Ensure that all driving functions (e.g. braking and
steering) are in good working order and note any unusual noises. Stop im-
mediately if you detect a malfunction.
Monitor the indicating instruments in the driver's cab continuously while

driving. In order to prevent accidents and damage, you must know what to
do if a warning light illuminates or an indicating instrument displays a crit-
ical value.
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30.03.2011

4 Driving
Always take the dimensions and driving char-

acteristics of your truck crane into account.
You must know the total weight and the axle
loads of your truck crane in order to avoid ex-
ceeding the weight restrictions on roads and
bridges as well as the load bearing capacity of
the ground.
You must know the width and height of your
truck crane in order to pass through narrow
and low places safely.
Always keep a sufficient distance away from

overhead cables and trolley-wire cables.
When driving, keep in mind that the boom of your truck crane protrudes
over the front of the driver's cab and the rear section of the crane swings out
around corners.
Keep a safe distance from buildings, poles or trees that are close to the edge
of the road. Have someone guide you in confined or blind areas. The banks-
man determines the driving speed and monitors the movements of your
truck crane. Use the agreed signals and hand signs.
On-road driving
Use the operating manual to determine
whether your truck crane is in the prescribed
condition for on-road driving (e.g. counter-
weight, hook block or lattice extension) before
setting off. Maintain this condition at all times
while driving.
Observe the applicable traffic regulations of

the country in which you are working. Keep in
mind that your truck crane is a large, heavy ve-
hicle that is to be driven with particular care
and prudence in heavy road traffic.
30.03.2011

4 Driving
Do not drive with all-wheel steering or activated differential locks.
Decrease your driving speed in good time when approaching sharp corners,
narrow places, places with low headroom, undulations and in particular rail-
road crossings with trolley-wire cables.
Always keep away from soft shoulders, as these could prove to be treacher-
ous traps for your truck crane.
Use extreme caution when driving on wet, slippery roads.
Driving on the site The site will often have soft, narrow driving paths. Refer to the sections Off-
road driving and Driving with a rigged crane depending on the specific operat-
ing conditions.
Have someone guide you whenever possible. If you must drive without the
help of a banksman, use the following horn signals to make your intentions
known:
I am driving forwards: 2 short blasts
I am driving backwards: 3 short blasts
I am stopping: 1 short blast
Do not drive on the site until you are certain that your path is clear. Drive
slowly.
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30.03.2011

4 Driving
Off-road driving You may not start off-road driving until:

– The boom is placed on the boom rest.
– The superstructure is locked into place and secured against turning.
– The hook block is secured and cannot swing.
You must know the load-bearing capacity of the terrain and the axle loads
of your truck crane for off-road driving. You must know when your truck
crane is no longer stable on inclines. You may only drive over an obstacle
(e.g. a large bump or a step in the ground) if you are certain that the truck
crane will not run aground. If you cannot drive over the obstacle straight on,
you must drive over it diagonally.
Please note that under certain circumstances the total weight and the indi-
vidual axle loads are greater when the crane is rigged than in on-the-road
driving mode (see Driving with a rigged crane in this section).
Make use of all of the devices on your truck crane that are designed to make
off-road driving easier.
Keep in mind that driving too quickly on rough terrain could cause damage
to your truck crane. Do not take this risk. The rougher the terrain, the slower
you should drive.
Only tow the truck crane free in reverse driving direction!

Only fasten the tow rope to the slinging points provided for this purpose.
The truck crane may only be towed straight out of its own track in reverse
direction. Pulling the truck crane in jolts or diagonally is strictly prohibited.
Support the towing manoeuvre with engine power of the truck crane.
30.03.2011

4 Driving
Driving with a Only drive a rigged truck crane if this is explicitly stated in the operating
rigged truck crane instructions.
You must know the load-bearing capacity of the route and the axle loads of
your truck crane. Only drive if the route is a flat, even surface. The operating
manual contains the conditions you must fulfil if you wish to drive the crane
while it is rigged (e.g. position of the superstructure, telescoping or boom
angle). The risk of overturning is particularly high when driving a rigged
truck crane.
Before driving, check the air pressure of the tyres when the tyres are cold.
The tyres become hot when driving, which increases the tyre pressure. Do
not let out any air pressure when the tyres are warm. When the air pressure
in the tyres is too low, the tyres are under extreme pressure and the truck
crane could overturn.
You must extend the outriggers before begin-

ning to drive in order to decrease the risk of
overturning. Extend all four outrigger beams
completely. Extend all outrigger cylinders un-
til the outrigger pads are just above the
ground.
Monitor the wind speed when driving a rigged
truck crane. You may only drive the truck
crane if the maximum permissible wind speed
is not exceeded.
The maximum permissible wind speeds that
apply to crane work also apply to driving a
rigged truck crane.
You must have a banksman guide you when driving a rigged truck crane.
Keep in mind that the steering behaviour of your truck crane will be differ-
ent.
Avoid jolting and braking suddenly. You may only drive at the prescribed
speed. While driving, ensure that neither the outrigger nor any other part of
your truck crane catches on an obstacle. Choose the largest possible turning
radius if you must drive around a corner.
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30.03.2011

4 Driving
Driving with a load The following safety instructions only apply if your truck crane is authorized
on the hook to drive with a load.
The safety instructions that apply to driving a rigged truck crane generally
apply to driving with a load on the hook. The following safety instructions
must also be observed:
Do not drive with a load on the hook unless this is explicitly stated in the
lifting capacity table.
Observe the lifting capacity table and the operating instructions. These con-
tain the conditions you must fulfil (e.g. position of the superstructure, tele-
scoping and RCL code) if you wish to drive with a load on the hook.
Driving with a hanging load is particularly dangerous.

You should therefore only drive with a load on the hook if absolutely neces-
sary. Prevent the load from swinging using holding ropes. Keep the load as
close to the ground and the truck crane as possible while driving.
The load can be transported on the carrying deck of some Manitowoc Crane
Group Germany GmbH truck cranes if they are properly secured.
30.03.2011

4 Driving
Driving from the The following safety instructions only apply if your truck crane can be driven
crane cab from the crane operator's cab.
The truck crane may only be driven if the route does not have a steep incline
or sloping ground. The truck crane may only be driven from the driver's cab
under such conditions.
Please note that the slewing direction on the steering wheel and the steering
angle of the wheels must not always correspond (see Driving from inside the
crane cab in the operating instructions).
Lock the parking brake in the crane cab after driving.
Driving with all- The following safety instructions only apply if your truck crane is equipped
wheel steering with all-wheel steering.
If all-wheel steering is activated, the rear axle lines and the front axle lines
may be steered separately.
Keep in mind that all-wheel steering changes the driving behaviour of your
truck crane while driving.
The turning circle of the truck crane will become smaller if you turn the
wheels of the front and rear axle lines in opposite directions.
The truck crane will move diagonally to the side if you turn the wheels of the
front and rear axle lines in the same direction (crab travel mode).
Return the truck crane to normal driving mode after driving with all-wheel
steering. Ensure that all-wheel steering has actually been switched off, par-
ticularly before on-road driving. Risk of accidents.
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30.03.2011

4 Driving
Driving with a Observe the regulations of the country in which you are working that apply
trailer to driving with a trailer.
Working with a trailer is only permitted if the truck crane is registered for
towing a trailer and has been equipped with the appropriate special equip-
ment (e.g. towbar coupling) by the manufacturer.
If this is the case, refer to the operating manual for further information about
towing a trailer.
Do not exceed the maximum permissible trailer load.
4.3 After driving
Choose a suitable, safe place to park your truck crane.

Do not park in areas in which the truck crane could slip or the ground could
be washed out.
Do not park on a hill. If you have no other place

to park, secure the truck crane using wheel
chocks to prevent it from rolling.
Always lock the parking brake after driving.

Your truck crane cannot be prevented from
rolling by selecting a gear position.
Lock the truck crane to prevent unauthorized

use.
Turn off the engine, remove the ignition key
and keep the key with you.
If you leave your truck crane for longer periods of time (e.g. overnight or
weekends) you must also turn off the battery master switch and remove the
spindle-shaped button. Lock the crane cab and the driver's cab and keep the
keys with you.
30.03.2011

5 Crane work
5 Crane work
The following safety instructions and precautionary measures for working
with the crane supplement the safety instructions and precautionary meas-
ures contained in the operating manual.
5.1 Before crane work
Cooperate with your supervisor and follow his instructions.

Report to your supervisor upon arrival at the site, have him explain the ap-
plicable safety regulations for the site and ask about the safety precautions
required for your work.
Choose a location on the site that will provide the truck crane with a firm
and secure holding and allow you to work safely.
Familiarize yourself with your work area and its surroundings before setting
up your truck crane. In particular, check whether electric cables, supply lines
(e.g. gas or oil) or other obstacles are hazardous for crane work. Mark these
locations as conspicuously as possible.
Park the truck crane as close as possible to the load that is to be lifted while
keeping a safe distance away from slopes and pits.
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30.03.2011

5 Crane work
The ground under the truck crane must be stable enough to withstand the
loads produced during crane work. If the ground under the truck crane gives
way, it could cause the truck crane to tip or overturn.
The ground under the truck crane should also be even in order to facilitate
the correct alignment of the crane.
Mark the entire danger zone of your truck crane using cordons, marker tape,
warning signs or other suitable materials.
Support the truck crane on outriggers before rotating the superstructure.

The truck crane may only be turned when it is not on outriggers if it is al-
lowed to carry out freestanding work in a slewing range of 360°, see operat-
ing instructions.
Observe the lifting capacity and outrigger pressure tables of your truck
crane. The surface pressure of the outrigger pads must never be greater
than the load bearing capacity of the ground. The truck crane may overturn.
The prescribed span may be found in the lifting capacity table. All outrigger
beams must always be extended to the same span unless otherwise stipu-
lated in the operating manual.
If you are forced to work with the truck crane

at a location at which the load bearing capacity
of the ground is insufficient, you must enlarge
the surface area of the outriggers using pack-
ing made of stable material (e.g. wooden
planks). The packing material must be able to
withstand the outrigger pressure during crane
work.
Monitor the movement of the outrigger beams

and outrigger cylinders when extending the
outrigger. Risk of crushing.
Use the outrigger cylinders to compensate for uneven ground. Do not ex-
tend one outrigger cylinder significantly more than the others. If the packing
material presses into the ground, the outrigger cylinders must have suffi-
cient remaining stroke in order to re-level the truck crane.
30.03.2011

5 Crane work
Ensure that your truck crane is horizontally aligned before carrying out
crane work.
Check that the truck crane is properly aligned using the circular spirit level.
Never attempt to tilt your truck crane to increase the working radius. The
truck crane must always be aligned horizontally. The truck crane may over-
turn.
Use only the steps and ladders when getting on and off your truck crane.
Use only the handles provided to keep a firm hold. Never hold onto control
levers, hoses or cables. Always make sure you have a solid foot-hold and
firm grip, particularly in wet conditions. Never jump from your truck crane
unless it is an emergency.
Never reach into movable components unless these are securely locked
against each other and the engines of both the vehicle and the crane are
shut off.
Inspect your truck crane. Walk around the truck crane before beginning
crane work.
Do not assume that everything is in working order simply because it was in
working order when work was last completed.
Check that all necessary safety devices (e.g. guards, covers and lighting) are
properly secured and in good working order.
Ensure that no fluids (e.g. oil, fuel or water)

have leaked or are leaking. Take the appropri-
ate measures. Seal the leak and dispose of the
leaked material accordingly.
If screws or nuts are loose, retighten the con-

nection and replace missing parts. This also
applies to line connections. Use only the orig-
inal spare parts provided by the manufacturer.
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30.03.2011

5 Crane work
Check the level of the fuel, engine oil, coolant, hydraulic oil and all other
consumables and lubricants. Only authorized consumables and lubricants
may be used for refilling.
Ensure that the seals, e.g. filler-necks and outlet sleeves, on all systems are
in place and secured properly.
Warning tags may be located in or on the truck crane.

Never start the engine if you find one of these tags anywhere. Wait until the
warning sign is removed by either the person who put it there or someone
who knows why it was put there.
Check in particular the hoist rope for wear,

bends and other damage. Replace a worn or
damaged hoist rope immediately. A descrip-
tion of possible hoist rope damage may be
found in the maintenance manual.
Ensure that the hoist ropes are not knotted or

entangled. The hoist ropes must be properly
attached to the deflection sheave and reeled
on the hoist drum in the prescribed manner.
Remove any loose objects from the truck

crane. Loose objects may fall off the truck
crane during crane work. Risk of accidents.
Even objects used by others (e.g. tools or beverage bottles) may not remain
on the truck crane. Remove these objects in order to prevent others from
walking into the danger zone during crane work.
Provide your banksman with a board containing the signals and hand signs
that are to be used during crane work.
Exhaust fumes are deadly. Ensure that you have sufficient ventilation if you
must start the engine in a closed room.
30.03.2011

5 Crane work
Check all operating elements in the crane cab before starting the engine for
crane operation.
Ensure that all operating elements are clean, dry, accessible and operable.
Remove any loose objects from the cab floor.
All operating elements that may cause the inadvertent movement of the
truck crane when the engine is started must be in zero position. All pedals
must be clean and dry. Keep the cab floor free of dirt and moisture to pre-
vent your feet from slipping off of the pedals.
Ensure that none of the vent grilles in the crane cab are covered (e.g. by
pieces of clothing or bags).
Adjust the seat in the crane cab and the mirror used to monitor rope running
accordingly.
Do not start the engine until you are sure that all preparatory work inside,
outside and in particular under the truck crane has been completed.
You may not start the engine unless you are sitting in the seat of the crane
cab. This is the only position from which you have control of all operating
elements and can quickly and properly react to potential danger.
Monitor all warning and indicator lamps as

well as the control instruments when the en-
gine is started.
Further information may be found in the oper-
ating instructions.
Do not begin rigging and crane work until the

hydraulic oil has reached its operating temper-
ature and you have checked all crane func-
tions.
Check, without a load on the hook, whether all
crane functions (e.g. raise, lower and tele-
scope boom, slew superstructure, hoists, rap-
id motion, engine speed and brakes) are in
good working order.
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30.03.2011

5 Crane work
Use only equipment that belongs to your particular truck crane

(e.g. counterweight).
The equipment of your truck crane was made to fit your truck crane only.
Your truck crane and its equipment have the same serial number. The truck
crane may only be operated with this equipment.
Observe the information in the lifting capacity table of your truck crane. If
your truck crane can be operated with different weights, the counterweight
sections may only be combined as defined in the lifting capacity table. Other
combinations are prohibited.
Use particular caution when stacking and lowering the counterweight sec-
tions. Ensure that no body parts or other objects get caught between the
counterweight sections. Keep a sufficient distance away. Risk of crushing.
30.03.2011

5 Crane work
Ensure that the equipment is slung securely.

The equipment of the truck crane (e.g. auxil-
iary hoist and counterweight) are provided
with holders specifically for this purpose. The
equipment is to be slung using these holders
only.
If your truck crane is equipped with removable

counterweight sections, you may only sling
one counterweight section at a time.
The safety instructions that apply to slinging

loads also apply to slinging the truck crane
equipment (see section During crane work).
Only mount the equipment as described in the operating manual of your

truck crane. Observe the prescribed assembly sequence.
Remove any loose objects from the equipment. Loose objects may fall off
the truck crane during crane work. Risk of accidents.
Check that all safety devices (e.g. RCL and lifting limit switch) are in good
working order. You cannot begin rigging and crane work unless all safety
devices are in good working order.
5.2 Rigging lattice extensions
Your truck crane may be equipped with various lattice extension systems:
two-stage swing-away lattice extension, telescopic swing-away lattice ex-
tension, power tilt jib, boom extension or luffing lattice extension.
All lattice extensions increase the reach and thus the application possibili-
ties of your truck crane. However, they also require special safety precau-
tions, both during rigging and crane work.
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30.03.2011

5 Crane work
When rigging the lattice extension, observe the specifications concerning

the required counterweights and outriggers, the permitted superstructure
position and the telescoping status of the main boom contained in the op-
erating manual.
Use the enclosed extendable ladder when rig-

ging and unrigging the lattice extension if you
need to reach higher areas. Never climb on the
main boom or the lattice extension unless
they are equipped with walkways or steps.
Never lean the extendable ladder against the
lattice extension, rather against the head of
the main boom, especially when rigging the
power tilt jib, as the power tilt jib moves dur-
ing rigging.
Do not support yourself on moveable parts (e.g. hydraulic hoses) when carr-
ying out rigging work on the ladder. Do not grasp bore holes or other nar-
row areas. When carrying out rigging work on the power tilt jib, find a
holding position which is as far away as possible from the locking cylinders
so as to prevent your fingers or hands from being crushed.
An auxiliary crane is necessary for the installation of the boom extension or

the luffing jib. An auxiliary crane is also required for swing-away lattice ex-
tensions and the power tilt jib in order to mount the lattice extension sec-
tions on the main boom.
When raising the lattice extension sections,

use only the lifting gear that corresponds to
the load.
Fasten them to the slinging points provided
for this purpose (if applicable).
If no fixed slinging points are provided, ob-

serve the centre of distribution of the individ-
ual lattice extension sections specified in the
operating manual.
30.03.2011

5 Crane work
Always insert the connecting pins from the outside inward. Fasten the pins
using retaining pins.
When rigging, ensure that the hoses and lines that lead from the main boom
to the lattice extension are laid in such a way that they cannot be damaged.
Connect the hoses and lines only as described in the operating manual.
Check that all safety devices (e.g. lifting limit switch) are in good working
order after rigging. Overriding the lifting limit switch is strictly prohibited.
Please observe the following special instructions for the power tilt jib:
You should under all circumstances follow the sequence of working steps
set out in the operating manual, as the power tilt jib may otherwise collapse.
When swinging the main jib to the front, only telescopic part II should be
extended. Extending any other telescopic part will damage the truck crane.
This applies to both rigging methods of the power tilt jib.
When rigging the hydraulic hoses, ensure that

the hoses that lead from the hose drum are
kept under tensile stress, particularly when
changing the retaining plate with the hydraulic
quick couplings.
You should therefore ensure that the ladder is
stable and that you have a good foothold on
the ladder.
Before swinging back the power tilt jib laterally to the main jib, plug the hy-
draulic hose holders into the mountings for main jib operation to protect
them from potential damage.
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30.03.2011

5 Crane work
Please observe the following special instructions for the boom extension
and the luffing jib:
You may only extend the boom extension or the luffing jib to the length
combinations that are specified in the operating manual as permissible
combinations. Other combinations are prohibited.
The rigging crew must pay particular attention and use extreme caution
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5 Crane work
5.3 During crane work
Never carry out crane work without the lifting capacity table of your truck
crane.
Never exceed the values specified in the lifting capacity table.
All specified lifting capacity values only apply to free-hanging loads. Note
the conditions (e.g. boom length, telescoping or RCL code) under which the
values may be reached.
The hoisting capacity of the crane depends on the tractive force of the hoist
and the number of reevings on the hook block. Further information may be
found in the operating instructions.
When determining the required lifting capacity, please note that the weight
of the hook block and the lifting gear must be added to the load. The actual
payload of the crane is therefore smaller than the value specified in the ta-
ble.
For increased operational safety the truck crane is equipped with a rated
capacity limiter (RCL).
The rated capacity limiter prevents the permissible load bearing capacity of
the truck crane from being exceeded.
However, the RCL cannot replace safe, responsible conduct.

Never use the RCL as a scale to determine the weight of loads.
The RCL does not automatically assimilate all

information in crane operation required to cal-
culate the load limit.
Some of this information must be entered on

the RCL control unit. Set these values accord-
ing to the actual rigging mode of the truck
crane.
If the incorrect information is entered, the

maximum load capacity calculated by the RCL
will not correspond with the actual permissi-
ble load capacity. Risk of accidents.
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30.03.2011

5 Crane work
The RCL only protects one-hook operation (load hangs from one hook
block).
The RCL does not protect two-hook operation (load hangs from two hook
blocks and is lifted using two independent hoisting gears).
Two-hook operation is therefore particularly dangerous.
It is strictly prohibited to operate the crane if the rated capicity limiter is
switched off, overridden, out of operation or defective!
The key for RCL overriding may not be left in the key switch during crane
operation.
You may only override the RCL if the operating manual or maintenance
manual explicitly require you to do so.
If the RCL malfunctions during crane operation, you may override the RCL
in order to set down the load. Under no circumstances are you to continue
working with an overridden RCL. If a load is still hanging from the hook, do
not perform any movements which increase the load moment (extending
the telescope, lowering the boom, slewing out of a restricted slewing
range). The truck crane may overturn.
Always remove the key from the RCL override key switch after overriding.
Repairs to the RCL may only be carried out by properly qualified personnel.
Ensure that the load is properly slung.

Observe the regulations of the country in which you are working that apply
to lifting tackle.
Establish the weight of the load before you sling it. Keep in mind that the
weight of hook blocks, ropes, chains, crossheads and other lifting tackle
must be added to the weight of the load. The lifting capacity of your truck
crane must be sufficient to lift the total load.
30.03.2011

5 Crane work
Make sure that the fail-safe device fitted to the

hook block is in perfect working order. Use
only suitable, undamaged lifting tackle with a
sufficient loading capacity for slinging the
load.
Never use the hoist rope to secure the load.
Never lift several loads simultaneously, even if

the lifting capacity of your truck crane is suffi-
cient to lift the load combination. This could be
hazardous.
The load must be slung in such a way that it is properly balanced and cannot
tip or fall. Use the slinging points provided for this purpose (if applicable).
Take care not to damage the load or its packaging when slinging the load.
This applies in particular to loads that could release harmful materials.
Align the boom so that the hoist rope hangs directly over the load.
Ensure that the lifting tackle and the load do not get caught anywhere when
slinging the load.
Check whether the load is fixed to the ground or the base. Never attempt to
pull off a fixed load. The truck crane may overturn.
Do not lift the load until the slinger gives the signal.
Never pull a load diagonally over the ground, even if it is on rollers. The re-
sulting tension could damage the boom and overload your truck crane.
Dragging is strictly prohibited.
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30.03.2011

5 Crane work
The entire working area of your truck crane must be properly illuminated
for night-time operation.
You and those around you must be able to see the movements of the crane
and the load clearly.
Keep a close eye on your working area at all times.

Everyone on the site must be a safe distance away before you may drive
your truck crane, turn the superstructure or move the load. Sound your horn
if anyone approaches the working area of your truck crane or the load. Stop
working if those in the danger zone do not move a safe distance away.
Never leave the crane cab while a load is hanging. Never switch off the
crane engine while a load is hanging. Always keep your hand near the con-
trol lever while a load is hanging. This enables you to react correspondingly
at all times.
Always put the load down before you stop work.
You must never swing or hold a load or the hook block over those on the
site. Keep in mind that people may also be sitting in driver's cabs or other
rooms.
Ensure that no one is standing or working under the load or any other part
of your truck crane during crane work.
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5 Crane work
Never overload your truck crane.

Listen for any unusual noises during crane work.
Accelerate and brake all crane movements slowly. Sudden acceleration or

braking will cause the load to swing or derrick. The boom could buckle or
your truck crane could overturn.
Ensure that your truck crane is horizontally

aligned at all times. Your truck crane must al-
ways be horizontal during crane work.
Sudden acceleration or braking or quick slew-

ing movements could cause the truck crane to
overturn if the boom length is long, even if the
hook does not have a load.
Never lift the load by raising the boom, as the

RCL does not function when this is carried out.
Dragging with the hoist rope is prohibited. When lifting a load, the hoist
rope must hang directly over the load throughout the entire procedure,
from the time the load is picked up until it is set down. The truck crane may
overturn.
Some Manitowoc Crane Group Germany GmbH truck cranes allow you to tele-
scope the main boom with a load on the hook block. You should not do this
unless the operating conditions make it absolutely necessary. Do not carry
out any other crane movements when telescoping with a load.
Do not allow the crane movements to be shut off by the safety devices
(e.g. RCL, lifting limit switch and lowering limit switch). Stop the respective
movement in good time.
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30.03.2011

5 Crane work
Strong winds, particularly gusts, can overload

the truck crane.
Monitor the wind speed on the anemometer
continuously during crane work or inquire
about this at the meteorological office in your
area. The permissible wind speed for a fully
loaded truck crane may be found in the lifting
capacity table. The appropriate measures for
excessive wind speeds and wind surfaces may
be found in the operating instructions.
Do not overload the hoist rope.

Take care that no objects hit against the load-
ed hoist rope. This can damage the rope.
Ensure that slack-rope does not occur when reeling off the hoist rope during
crane work. Slack-rope causes rope loops to form on the hoist drum which
can lead to load slipping and thus damage the hoist rope.
Ensure that the working area is clear before every crane movement.
Do not touch any other parts when moving the load and the boom or turn-
ing the superstructure.
Crane work must be terminated immediately if you touch other equipment
or parts of your truck crane during the movement. Check your truck crane
for damage. Do not continue to work unless your truck crane is operational-
ly safe.
Keep an eye on the load at all times during crane work. Restrict the move-
ment of the load using holding ropes. Holding ropes must never be
wrapped around any part of the person(s) holding them, as the ropes must
be released quickly to avoid injury in potentially dangerous situations.
30.03.2011

5 Crane work
Never lift people with the hook block or the

load.
This is extremely dangerous and thus strictly
prohibited. Only use authorized means for
transporting and lifting persons (such as work-
ing cages).
Crane operation When operating the crane with lattice extensions, you must keep in mind
with a lattice that the truck crane is more sensitive to braking and accelerating crane
extension movements than under normal conditions.
You should therefore avoid movements that could be shut of by the RCL
when working with lattice extensions. Automatic shutdown by the RCL may
cause swinging that could overload the truck crane.
Perform all crane movements as smoothly as possible in order to avoid

overloading and swinging.
When working with lattice extensions, observe the specifications concern-

ing the required counterweights and outriggers and the telescoping status
of the main boom contained in the operating manual.
Telescoping the main boom with a load on the lattice extension is strictly
prohibited.
A hook block may be reeved on the main boom during operation with the
power tilt jib. No load, however, may be attached to this hook block. The lift-
ing capacity at the power tilt jib must then be reduced according to the lift-
ing capacity table.
The power tilt jib may be derricked and telescoped during operation with a
loaded hook.
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30.03.2011

5 Crane work
The lifting capacity on the power tilt jib is fixed for certain angles of the PTJ
(fixed angles) and lengths of the PTJ (fixed lengths). The lifting capacity is
lower between the fixed angles and fixed lengths (refer to the lifting capacity
table).
The main boom can also be derricked with a load on the hook of the power
tilt jib.
When working with the lattice extension, the lifting capacity of the lattice ex-
tension decreases if a hook block remains reeved to the main boom.
This applies in particular if the lattice extension remains mounted to the
main boom when working with the main boom.
The specific lifting capacity reductions for both of these cases may be found
in the comments of the lifting capacity tables.
Two-hook operation in connection with the lattice extension and the main
boom is prohibited. The RCL does not protect two-hook operation! Two-
hook operation can cause the truck crane to overload.
You may not override the RCL during crane

work with lattice extensions.
When working with the lattice extension, it is imperative that you observe
the permissible wind speed specified in the lifting capacity table and the op-
erating manual. You must stop working and take the appropriate safety pre-
cautions (e.g. turn the truck crane into the wind) if the wind is too strong.
30.03.2011

5 Crane work
Two-hook In two-hook operation, the load hangs on two hook blocks and is lifted using
operation two independently operated hoists.
Working simultaneously with two hook blocks on the boom is particularly

dangerous.
for two-hook operation.
The RCL only protects crane operation when

one hook block is on the boom.
Two-hook operation is not protected by the
RCL. The stability of the truck crane is at risk
without RCL monitoring.
You should therefore move the load at the

lowest possible speed and use extreme cau-
tion when working in two-hook operation.
This prevents the truck crane from overload-
ing.
Working with a Do not work with a truck crane which is free on wheels (i.e. which is not on
free-standing outriggers) unless this is explicitly permitted in the lifting capacity table.
truck crane Observe the lifting capacity table and the operating instructions. These contain
the conditions you must fulfil (e.g. slewing range of the superstructure, tel-
escoping and RCL code) when working with a free-standing crane.
Leave all four outrigger beams completely extended when working with a
truck crane which is free on wheels. Extend all outrigger cylinders until the
outrigger pads are just above the ground.
Before beginning crane work, check the air pressure of the tyres when the
tyres are cold. The tyres become hot when driving, which increases the tyre
pressure. Do not let out any air pressure when the tyres are warm. When the
air pressure in the tyres is too low, the tyres are under extreme pressure and
the truck crane could overturn.
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30.03.2011

5 Crane work
Working with Working with an attached solenoid is only permitted if the truck crane has
attached solenoid been equipped with the appropriate special equipment by the manufacturer
(e.g. power failure safety device or lifting capacity table).
Observe the regulations of the country in which you are working that apply
working with an attached solenoid.
Never lift fixed loads when working with an attached solenoid.
Working with two

cranes
Working with two cranes is particularly dangerous.

Should it be necessary to work with two cranes, both cranes should have
the same characteristics (truck cranes with telescopic booms) if possible.
The weight of the load should not exceed 2/3 of the overall lifting capacity
of both cranes. Do not overload one of the two cranes. The maximum lifting
capacity of each individual crane must not be exceeded.
Distribute the load on both cranes according to the respective lifting capac-
ities. This applies in particular when the distribution of the weight of the
load is unequal or an asymmetrical crosshead is used.
Always have someone guide you. Only one banksman should give the sig-
nals for both cranes. Before commencing work, sit down together and plan
how you will proceed. Ensure that neither crane pulls the load diagonally.
The hoist rope of each of the two cranes must always hang vertically.
30.03.2011

5 Crane work
5.4 After crane work
Work break Always put down the load before you stop work.
Never leave the crane cab while a load is hanging on the hook block.
Retract the boom as far as possible if leaving the crane for over 8 hours.
Lock the truck crane when you leave the cab

to prevent unauthorized use during your work
break.
Turn off the engine, remove the ignition key
and keep the key with you.
If you leave your truck crane for longer periods
of time (e.g. overnight or weekends), turn off
the battery master switch and remove the
spindle-shaped button.
Lock the crane cab and the driver's cab and

keep the keys with you.
Unrigging the Ensure that the truck crane is in the prescribed transport condition.
truck crane All of the steps that you must carry out may be found in the respective sec-
tions of the operating manual.
Keep in mind that you may not retract the outrigger until the superstructure
has been turned forward to driving direction and the main boom has been
set down on the boom support.
The truck crane is most likely not on outriggers if it can work in a free on
wheels condition with a slewing range of 360°. If the crane is not on outrig-
gers, the superstructure may not be turned unless this is explicitly stated in
the operating instructions.
Monitor the movement of the outrigger beams and outrigger cylinders

when retracting the outrigger. Risk of crushing.
Retract the outrigger cylinders alternately by a maximum of 10 cm. The
truck crane may overturn.
Do not retract the outrigger beams until all outrigger pads are lifted off the
ground.
30.03.2011

5 Crane work
Blank page
30.03.2011

6 Crane operation under special operating conditions
6 Crane operation under special operating

conditions
The following safety instructions and precautionary measures for crane op-
eration under special operating conditions supplement the instructions con-
tained in the operating manual.
6.1 During the winter
Special measures must be taken to protect the truck crane if the outdoor
temperature exceeds or falls below the permissible temperature range for
crane work. The specific steps that you must carry out are described in the
operating manual.
In extreme frost, do not touch any metal surfaces with moist or wet skin, as
the skin will freeze immediately.
Remove all snow and ice from the truck crane

before beginning crane work.
Ice and snow must also be removed from the
boom and the load. The additional weight can
overload your truck crane.
Do not store any full or empty containers with

cold-start agents or any other inflammable liq-
uid on the truck crane. Keep any such contain-
ers away from heat, sparks and open flames.
Do not smoke when working with cold-start
agents or any other inflammable liquids. Emp-
ty containers may explode if they are punc-
tured or burned.
You may only wear gloves made of soft leather and a thin lining when driv-
ing and working with the crane. You cannot work the operating instruments
properly if you are wearing mittens or thick working gloves, and your fin-
gers could slip when wearing gloves made of wool or synthetic material.
The operating instructions explain the proper procedure for starting the
truck crane in low temperatures. Do not begin crane work until the hydraulic
oil has reached its operating temperature.
30.03.2011
Before lifting the load, check whether it has frozen to the ground or the base.
Never attempt to pull off a frozen load. The truck crane may overturn.

6.2 Working near electric cables
Crane work carried out in the vicinity of electric cables is dangerous and
requires special precautionary measures.
when carrying out work in the vicinity of electric cables.
Contact the responsible electricity company. Inquire about the voltage and
the required safe distances. Establish the necessary safety precautions for
the banksman. It is your responsibility to ensure that the necessary precau-
tionary measures be introduced.
Before commencing work, inform everyone that they are not to touch the
crane or the load when working near electric cables.
Tell your helpers (banksmen, slingers) what to do if someone suffers an
electric shock. Further information may be found in the operating instructions.
Always have a banksman guide you when working near electric cables. The
banksman must be able to monitor the movement of the truck crane from a
suitable location and inform you if the truck crane or the load approaches
electric cables. The banksman must be able to communicate with you di-
rectly and you must concentrate on the signs and signals he gives you.
Always maintain a safe distance when working near electric cables.
You must always carry out all prescribed safety measures, even if your truck
crane is equipped with a high voltage warning device. However, the RCL
cannot replace safe, responsible conduct.
30.03.2011

6.3 Working near strong high-frequency transmitters or in

potentially stormy weather
Both the truck crane and the load may become electrostatically charged
when working within the range of strong high-frequency transmitters or in
potentially stormy weather.
This applies in particular if the truck crane is equipped with synthetic outrig-
ger pads or the outrigger pads are packed with insulated material (e.g.
wooden planks). It is therefore necessary to earth your truck crane.
Ensure that the connection between the truck crane and the ground is a
faultless, electrically conductive connection.
Fasten the earth cable on the truck crane to the welded parts of the boom
or the superstructure only. Do not fasten the cable to screwed on parts
(e.g. valves, cover plates, engines or transmissions).
Contact the broadcaster before commencing work within the range of high-
frequency transmitters. The earthed truck crane can disturb transmission.
Tell your helpers (banksmen, slingers) what to do if someone suffers an

electric shock. Further information may be found in the operating instructions.
The load on the hook of your truck crane may also become electrostatically
charged when working within the range of strong high-frequency transmit-
ters or in potentially stormy weather.
This applies in particular if a hook block is used with synthetic sheaves and
non-conducting lifting tackle (e.g. synthetic or manila hemp rope). You
should therefore earth the load.
Use only a metal rod with an insulated handle

to earth the load. The metal rod is to be held
by the insulated handle only.
Accidents may occur due to an electric shock.
Tell your helpers (banksmen, slingers) that
they must not touch the load until after it has
been earthed.
Accidents may occur due to an electric shock.
30.03.2011

6.4 Working near supply lines (e.g. oil or gas)
Crane work carried out in the vicinity of supply lines is dangerous and
requires special precautionary measures.
when carrying out work in the vicinity of supply lines.
You must contact the responsible supply company if harmful materials are
transported in a supply line. Discuss suitable safety measures with the sup-
ply company. and establish the necessary safety precautions for the banks-
man.
It is the responsibility of you and the supply company to ensure that the nec-
essary precautionary measures be introduced.
Always have a banksman guide you when working near supply lines in
which harmful materials are transported. The banksman must be able to
monitor the movement of the truck crane from a suitable location and in-
form you if the truck crane or the load approaches the supply line. The
banksman must be able to communicate with you directly and you must
concentrate on the signs and signals he gives you.
Always keep a safe distance away from the lines. You must always assume
that the lines are under pressure, even if they have been interrupted.
30.03.2011

7 Proper conduct in the event of malfunctions, accidents and fires
7 Proper conduct in the event of malfunctions,

accidents and fires
The following safety instructions and precautionary measures for malfunc-
tions, accidents and fires supplement the instructions contained in the op-
erating manual.
Fuse change Always replace a blown fuse with a fuse of the same strength.
Never repair a blown fuse with a nail, wire or aluminium foil. Risk of fire.
7.1 Breakdown in road traffic
for proper conduct in the event of a breakdown.
If your truck crane breaks down, do not stop in a tunnel or around a corner
unless absolutely necessary, as the risk of accidents is much higher.
Activate the hazard warning lights and safeguard the truck crane. Use the
appropriate signs and devices to indicate that your vehicle has broken
down.
Safeguard the area around your vehicle.

Warning Triangles, signal lamps and torches
must be set up in front of the breakdown area
in such a way as to prevent rear-end collisions,
particularly in curves.
Do not try to repair the damage yourself until

the area has been safeguarded.
Do not attempt any repair work if the truck
crane is parked in a tunnel.
Risk of accidents.
s
30.03.2011

Tyre change Change the tyre on the flattest possible area of the traffic lane. The chosen
location should not impede traffic or pose danger to you or the vehicle.
Use only the original spare wheel of your truck

crane. Have someone help you change the
tyre if possible.
You should use the supplied spur-wheel chain

hoist to lift the spare wheel.
The truck crane wheel is heavy and could
cause injury. Move back quickly if the wheel
slips off the hub.
Check the wheel rim, the wheel, the wheel

nuts, the pressure plates and the wheel bolts
for damage before mounting the spare wheel.
Do not use any damaged parts when mount-
ing the spare wheel.
Retighten the wheel nuts of the mounted wheel after travelling approx.
50 km and again after approx. 150 km (see maintenance manual).
Tilting the driver's The driver's cab of some Manitowoc Crane Group Germany GmbH truck cranes
cab must be tilted in order to reach the vehicle engine.
You must first remove all loose objects from the driver's cab and remove
the front grille under the windscreen before tilting the driver's cab. Raise the
main boom far enough that the driver's cab will not hit the main boom when
it is tilted.
If the engine fails and your truck crane is a single-engine truck crane (only
one engine for driving and crane operation), you may use the emergency fa-
cility to lower the hook block and raise the main boom. The driver's cab may
then be tilted.
Ensure that the windscreen of the driver's cab does not press against the
hook block.
You may only work under the tilted driver's cab if it has been tilted forward
completely and the lifting cylinder of the driver's cab tipper device is pulled
under tension.
30.03.2011

7.2 Towing
Towing away Observe the regulations of the country in which you are working that apply
to towing.
You may only tow the truck crane short distances. If the parking brake was
mechanically released before towing, you must secure your truck crane us-
ing chocks. Otherwise, it could roll away.
If the vehicle engine, the steering and the service brake are still in good
working order, you may tow the truck crane with a truck and tow-rod.
If the vehicle engine, the steering and the service brake are no longer in
good working order, you must tow the truck crane with a towing vehicle and
a tow-rod.
Ensure that the braking force of the towing vehicle is sufficient to brake both
vehicles and that the air supply of the tractor-vehicle is sufficient for both ve-
hicles.
The towing vehicle must start driving slowly. Avoid jolting and accelerating
quickly. Drive carefully when towing.
Tow starting The diesel engine cannot be started by tow starting due to the automatic
transmission.
30.03.2011

7.3 Crane operation malfunctions
Put down the load immediately, if possible. Retract the boom completely
and set it down on the boom rest.
Put up an appropriate warning sign in the crane cab. Always remove the
ignition key before leaving the crane.
Accidents may occur if you are unable to set down the load due to a mal-
function. In this case, remove the ignition key before leaving the crane and
safeguard the danger area.
7.4 Accident
If an accident occurs, you must be able to give first aid and know where to
find additional help.
7.5 Fire
In the event of a fire, you must know how to

use the appropriate equipment and a fire ex-
tinguisher and know where to find additional
help.
30.03.2011

8 Transporting the truck crane on a separate vehicle
8 Transporting the truck crane on a separate

vehicle
The following safety instructions and precautionary measures for transport
supplement the instructions contained in the operating manual.
that apply to truck crane transport. In addition, please observe the pre-
scribed safety measures of the shipper (e.g. the carrying agent or railway
company).
Ensure that the truck crane is in the prescribed condition for on-road driving
before loading it onto the transport vehicle.
The truck crane may only be transported on a vehicle with sufficient load
bearing capacity.
8.1 Loading the truck crane yourself
Use extreme caution when loading and unloading the truck crane.
Use chocks to prevent the truck crane from rolling in both directions when
loading it onto and unloading it from the transport vehicle.
Loading and unloading must be carried out on flat, even ground. Use only
ramps with sufficient load bearing capacity when driving onto and off the
transport vehicle.
Secure the truck crane on the transport vehicle using chocks and a suitable
30.03.2011
chain both lengthwise and crosswise.

Secure all loose objects both in and on the truck crane.

8 Transporting the truck crane on a separate vehicle
8.2 Loading the truck crane with another crane
Use only suitable lifting gear with sufficient load bearing capacity to load
the truck crane. Be careful not to damage the truck crane when attaching the
lifting gear. Further information may be found in the operating instructions.
30.03.2011

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Safety Manual

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Fax: +[49] (0) 44 21 294-301

3 112 254 en Safety Manual

3 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

1-2 3 112 254 en Safety Manual

1 About this safety manual

The safety manual contains:

– Information about the proper use of your truck crane.

Safety Manual 3 112 254 en 1-1

Always observe the laws and regulations of

The truck crane manufacturer is not liable for

The manufacturer has no direct influence on

1-2 3 112 254 en Safety Manual

Proper use also includes:

– Observation of the complete crane documentation, consisting of the op-

Safety Manual 3 112 254 en 1-3

Improper use includes:

– Transporting loads on the carrier.

1-4 3 112 254 en Safety Manual

3 General Safety Instructions

You are personally responsible for safety.

Read the warning and information signs on

Safety Manual 3 112 254 en 1-5

3.1 The truck crane as a vehicle and a crane

Only operate the truck crane at permissible outdoor temperatures.

Your truck crane must be roadworthy and in good working order.

1-6 3 112 254 en Safety Manual

All maintenance and repair work must be

Carry out the prescribed inspections daily be-

Observe the prescribed maintenance inter-

Only original manufacturer replacement parts may be used if any parts

Safety Manual 3 112 254 en 1-7

3.2 You as the crane operator

• You must possess the prescribed authoriza-

1-8 3 112 254 en Safety Manual

Wear the prescribed articles of protective

When working with ropes and chains, always

Keep your eyes on the load or the banksman.

Stop working when you feel tired and can no

Notify your relief operator.

Safety Manual 3 112 254 en 1-9

3.3 Helpers (banksmen, slingers, guides for holding ropes)

You are responsible for the safety of your helpers.

1 - 10 3 112 254 en Safety Manual

3.4 Signals and hand signals

Signal systems that are not based on hand

I understood your signal: 1 short blast

To get attention: 1 very long blow

Hand signals for driving with the truck crane

Drive to the right

Drive to the left

1 - 12 3 112 254 en Safety Manual

Drive forward and show distance

If necessary, show distance with both hands.

Safety Manual 3 112 254 en 1 - 13

Hand signals for driving with the truck crane

Drive to the right

Drive to the left

1 - 14 3 112 254 en Safety Manual

Drive backwards and show distance

If necessary, show distance with both hands.