Böcker AHK 30/1400 User manual

Operating instructions
Trailer Crane
AHK 30/1400
02/2008
BWA000223

Trailer Crane AHK 30/1400
2 02/2008
© Böcker Kran- und Aufzugstechnik
Lippestr. 69
D-59368 Werne
Tel.: +49 (0) 2389 / 7989-0
Fax: +49 (0) 2389 / 532204
Internet: www.boecker-group.com
Dok-ID: 00985

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02/2008
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Introduction.......................................................................................................................... 7
1 General .............................................................................................................................. 8
1.1 Information about the Operating Manual....................................................................... 8
1.2 Applicable Documents ..................................................................................................8
1.3 Explanation of symbols.................................................................................................9
1.4 Safety Signs and Labels on the Device....................................................................... 10
1.5 Liability and Guarantee............................................................................................... 19
1.6 Copyright .................................................................................................................... 19
1.7 Spare parts................................................................................................................. 20
1.8 Dismantling................................................................................................................. 20
1.9 Disposal...................................................................................................................... 21
2 Safety............................................................................................................................... 22
2.1 General....................................................................................................................... 22
2.2 Responsibility of the Customer ................................................................................... 23
2.3 Possible misuse.......................................................................................................... 24
2.4 Implementation Conditions ......................................................................................... 24
2.5 Work safety................................................................................................................. 25
2.6 Personal safety equipment ......................................................................................... 25
2.7 Hazards that Can be Associated with the Device........................................................ 26
2.8 Safety Instructions in Accordance with BGV D6.......................................................... 29
2.8.1 Inspections ........................................................................................................... 29
2.8.2 Special Instructions .............................................................................................. 33
2.9 EMERGENCY-STOP SWITCH................................................................................... 33
2.10 Operating Personnel................................................................................................. 34
2.10.1 General............................................................................................................... 34
2.10.2 Qualifications...................................................................................................... 34
2.10.3 Physical Qualifications........................................................................................ 35
2.10.4 Behavior of Operating Personnel........................................................................ 36
2.11 Behavior in the Event of Danger or Accident............................................................. 37
3 Technical data................................................................................................................. 38
3.1 Rating Plate................................................................................................................ 41
3.1.1 Rating Plate Crane- Superstructure...................................................................... 41
3.1.2 Trailer Rating Plate............................................................................................... 41

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3.2 Maximum Slewing Range Crane Mode......................................................................42
3.3 Telescoping Dimensions.............................................................................................43
4 Device Structure and Function ..................................................................................... 46
4.1 General description.....................................................................................................46
4.2 Description of modules ...............................................................................................47
4.3 Telescoping System....................................................................................................48
4.4 Load Moment Device..................................................................................................49
4.5 Control Cabinet...........................................................................................................51
5 Transport......................................................................................................................... 52
5.1 Transfer/Delivery ........................................................................................................52
5.2 Prior to Transport........................................................................................................52
5.3 Coupling .....................................................................................................................58
5.4 During Transport.........................................................................................................65
5.5 Uncoupling, parking ....................................................................................................66
6 Setup................................................................................................................................ 70
6.1 Safety instructions ......................................................................................................70
6.2 Warning: suspended loads..........................................................................................71
6.3 Site Inspection ............................................................................................................72
6.4 Safety distance to power lines ....................................................................................74
6.5 Setup ..........................................................................................................................76
6.5.1 Starting the petrol engine......................................................................................76
6.6 Setting up and Aligning the Outriggers........................................................................87
6.6.1 Setup , Extend......................................................................................................94
6.7 Adjusting the Fly Jib Boom........................................................................................103
6.8 Supplemental Hook Weight.......................................................................................108
6.9 Load Diagram ...........................................................................................................110
6.10 Beaufort Scale ........................................................................................................111
7 Operation....................................................................................................................... 112
7.1 User/Loader Instruction............................................................................................. 113
7.2 Work Interruption Measures......................................................................................113
7.2.1 Work Break Measures ........................................................................................113
7.2.2 End of Work Measures .......................................................................................114
7.2.3 Measures When Resuming Work .......................................................................114
7.3 Crane Operation .......................................................................................................115

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7.4 Movement of load ..................................................................................................... 117
7.5 Remote Control ........................................................................................................ 119
7.6 Maneuvering Drive (optional)................................................................................... 122
7.6.1 Activating Maneuvering Drive ............................................................................. 122
7.6.2 Operating maneuvering drive.............................................................................. 125
7.6.3 Deactivate maneuvering drive ............................................................................ 126
8 Dismantling ................................................................................................................... 129
8.1 Dismounting the Device............................................................................................ 129
8.2 Dismounting the Outriggers ...................................................................................... 137
9 Storage .......................................................................................................................... 141
10 Maintenance................................................................................................................ 143
10.1 General................................................................................................................... 143
10.2 Regular Operator Checks ....................................................................................... 145
10.2.1 Prior to Each Transport in Road Traffic............................................................. 145
10.2.2 Prior to Each Use ............................................................................................. 146
10.3 Operating Hour Meter ............................................................................................. 147
10.4 Regular Maintenance by Qualified Personnel ........................................................ 148
10.4.1 General Inspections.......................................................................................... 149
10.4.2 Engine tests...................................................................................................... 151
10.4.3 Mechanical Inspections .................................................................................... 152
10.4.4 Hydraulic Inspections........................................................................................ 155
10.4.5 Electrical Inspections........................................................................................ 157
10.5 Recurring Inspections............................................................................................. 157
10.6 Verification of Theoretical Service Life.................................................................... 158
10.7 Maintenance documentation................................................................................... 158
10.8 Fuels and lubricants................................................................................................ 159
10.9 Tightening Torques................................................................................................. 160
11 Malfunctions................................................................................................................ 161
11.1 Safety Instructions .................................................................................................. 161
11.1.1 Minor Malfunction/Operating Error.................................................................... 161
11.1.2 Major Malfunction ............................................................................................. 162
11.2 Malfunction Table ................................................................................................... 165
11.3 Mitsubishi engine fault indicator.............................................................................. 166
11.4 Emergency Activation ............................................................................................. 167

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11.4.1 Emergency Operation - Crane Mode ................................................................168
11.4.2 Electrical-hydraulic methods.............................................................................172
11.4.3 Hydraulic Method..............................................................................................175
11.4.4 Emergency Activation - Hydraulic Outriggers....................................................178
12 Accessories................................................................................................................. 180
13 Appendix ..................................................................................................................... 183
13.1 Troubleshooting ......................................................................................................183
13.1.1 Motor does not Start .........................................................................................183
13.1.2 Motor does not Start (only Mitsubishi model ) ................................................... 184
13.1.3 Check Remote Control System......................................................................... 185
13.1.4 Check Support Mode........................................................................................ 186
13.1.5 Check Rotary Function .....................................................................................187
13.1.6 Check Telescoping Function.............................................................................188
13.1.7 Check Mast Lifting Function..............................................................................189
13.1.8 Check Cable Winch Function............................................................................190
13.1.9 Check Telescoping Mast Lowering, and Telescope Out Function..................... 191
13.1.10 Check Cable Winch and Telescope Out Function........................................... 192
13.1.11 Check Movement Functions with the Remote Control System........................193
13.1.12 Overload Light is Flashing ..............................................................................194
13.1.13 Overload Light Illuminated ..............................................................................195
13.2 Instruction Check List..............................................................................................196
13.3 Referenced documents...........................................................................................197
14 Index ............................................................................................................................ 199
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Trailer Crane AHK 30/1400
Introduction
02/2008 7
Introduction
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We are pleased that you have selected a high-quality, technical product from Böcker.
This operating manual contains detailed information about operation, maintenance, and care,
and rectification of malfunctions. It is a component of the device and must always remain
with the device (even if the device is sold) and it must always be available to every user.
Every operator, before he
places the device in service,
rectifies a malfunction, or
executes maintenance or repair work
must read the operating manual!
The load suspension gear is described in a separate manual. The accompanying assembly,
operating, and maintenance manuals provided by the respective manufacturers apply for
axles, overrun devices, and the drive.
Device failure can usually be attributed to improper operation, inadequate care and
maintenance, or unauthorized modifications. Modifications to the device are only permitted
with the manufacturer's written consent. Modifications, conversions, the bypassing of safety
devices, interventions in the electronics and sensor systems, displacement of valves, and
operating errors are prohibited. Inadequate maintenance releases the manufacturer from
any liability whatsoever.
Due to the variety of device types, the illustrations in this technical documentation are not
always identical with your device, rather they are provided only as an example of one variant.
We expressly declare that no claims can be derived from the information in this operating
manual.
Only use original replacement parts. Only original replacement parts guarantee safe and
reliable operation. To order replacement parts, please see our contact information at
www.boecker-group.com.
Our General Terms and Conditions, which are available at anytime at
www.boecker-group.com apply for guarantee and warranty. We would also be pleased to
send you a copy our General Terms and Conditions per post.
We wish you good work and a safe trip!
Albert Böcker GmbH & Co. KG
(We reserve the right to make technical changes in the interest of enhancements)
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General
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1 General
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1.1 Information about the Operating Manual
This operating manual describes operation and maintenance of the device. Compliance with
the specified safety instructions and handling instructions is the prerequisite for safe work
and proper handling of the device.
In addition, applicable local regulations for the prevention of industrial accidents and general
safety regulations must be complied with.
The operating manual is part of the product and must be kept accessible in the immediate
vicinity of the device for installation, operating, maintenance, service, and cleaning purposes.
The graphic illustrations in this manual are provided for purposes of better presentation and
explanation of content, they are not necessarily true to scale and can deviate slightly from
the actual version of the device.
In addition to this operating manual the operating manuals of the installed components also
apply. The instructions contained therein - particularly the safety instructions - must be
complied with!
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1.2 Applicable Documents
Components supplied by other manufacturers are installed in the device (e.g. drive motors).
These purchased subassemblies have been subjected to hazard evaluations by their
manufacturers. Compliance of the designs with applicable European and directives has been
declared by the manufacturers of the components.
The Declarations of Conformity of these manufacturers, as well as the operating,
maintenance, and repair instructions for the respective device components are inseparable
components of this device documentation. Operating personnel must comply with
instructions relative to safety, setup and installation, maintenance, dismounting, and disposal
of the components as contained in the manufacturer's documentation.
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1.3 Explanation of symbols
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Important safety and technical device instructions are identified by warning notices in this
operating manual. The warnings must be strictly heeded to prevent accidents, personal
injury, and property damage.
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WARNING!
This symbol is used to label dangers that can result in damage to health, injury,
disability or even death.
Strictly adhere to the associated safety instructions and always proceed with
special caution!
ATTENTION!
This symbol is used to identify instructions where non-compliance might result
in damage to property, malfunction and/or failure of the machine.
NOTE!
This symbol is used to identify tips and other information that should be observed in
order to ensure efficient and trouble-free operation of the machine.
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The following symbols have been used to make the operating manual more understandable:
Indicates component with its own operating manual
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1.4 Safety Signs and Labels on the Device
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Check the warnings and instruction notices affixed to the device for completeness and
damage prior to each start-up, and when executing maintenance work.
• Warning sign "High voltage".
Unauthorised persons are forbidden to
open the switch cabinet.
The sign is mounted on the switch box.
Abb. 1: High tension
• Warning „Emergency lowering“.
The sign is on the rear of the superstructure.
Abb. 2: Emergency lowering
• Warning sign "Support operation".
This sign provides a summary
description of the functions.
The sign is on the right rear of the chassis.
Abb. 3: Crane support activation
• Warning "Telescoping the main mast
is prohibited if ...". The sign warns of
dangers if the instructions are not
heeded.
The sign is mounted on both sides of the fly
jib boom.
Abb. 4: Telescoping

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• The sign provides a summary
description of the operating functions.
The sign is mounted on the valve plate for
emergency activation.
Abb. 5: Control block
• Warning sign "Risk of tipping". The
sign shows the maximum permissible
support load.
The sign is mounted on each outrigger.
Abb. 6: Max. permissible support load
• Sign „Change filter“. The sign includes
the date of the last filter change and the
name of the installer.
The sign is on the hydraulic oil tank.
Abb. 7: Change filter
• Warning "Excess pressure in the
tank". The sign warns dangers if the
instructions are not heeded.
The sign is mounted on the hydraulic tank.
Abb. 8: Hydraulic installation
• Warning sign " Hot surfaces".
Touching can cause first-degree to
second-degree burns. Do not touch if
possible or switch off the component
and allow to cool.
The sign is mounted on the motor hood and
on the hydraulic tank.
Abb. 9: Hot surfaces

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• Sign "Manoeuvring drive". The sign
provides brief operating instructions.
The sign is on the left of the chassis.
Abb. 10: Control block for travel
• Warning "Maneuvering drive".
The sign is mounted on the right and left
sides of the chassis (only for versions with
maneuvering drive).
Abb. 11: Uncoupling manoeuvring drive
• Switch and indicator light designations.
The sign is mounted on the switch box.
Abb. 12: Switch and indicator light
designations

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• Sign "Folding luffing boom in and
out".
The sign is mounted on the right of the
superstructure.
Abb. 13: Folding luffing boom in and out
• Sign „Stop cock“.
The sign is on the left of the superstructure.
Abb. 14: Stop cock
• Sign „Emergency activation“.The sign
warns of dangers if the instructions are
not heeded.
The sign is on the rear of the superstructure.
Abb. 15: Emergency activation
• Tire pressure specification
The sign is mounted on the fender.
Abb. 16: Air pressure specification
• Sign "Load winch during installation".
The sign is mounted on the switch box.
Abb. 17: Lastwinde bei Montage

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• Warning "Swinging of the load is
prohibited". The sign warns of dangers
if the instructions are not heeded.
The sign is on the right of the superstructure.
Abb. 18: Swinging of the load is prohibited
• Safety instructions for handling fuels.
• Specification of pump octane rating.
The sign is mounted on the fuel tank.
Abb. 19: Petrol
• Warning "Max. loads at different
telescope settings".
The sign is on the right of the superstructure.
Abb. 20: Maximum load of jib

Trailer Crane AHK 30/1400
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• Sign „Operation diagram“.For more
detailed information, see "Operating
diagram".
The sign is mounted on the right of the
superstructure.
Abb. 21: Operation diagram
• Warning sign "Locking tab". The sign
shows the maximum permissible loads
for the respective configuration.
The sign is attached at the right and left
locking tab.
Abb. 22: Locking tab
• Warning "Do not touch the winch".
The sign is mounted on the right and on the
left of the winches.
Abb. 23: Winches
• Warning „Access to the working and
slewing area is not allowed!“.
The sign is mounted on the rear of the
superstructure.
Abb. 24: Slewing area

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• Warning„Danger of tipping limit“.The
sign warns of dangers if the instructions
are not heeded.
The sign is located behind the panelling at the
rear of the superstructure.
Abb. 25: Danger of tipping limit
• Warning "Hook weight". The sign
warns of dangers if the instructions are
not heeded.
The sign is on the right of the superstructure.
Abb. 26: Hook weight
• Warning "Damage to connecting
hoses during emergency operation".
The sign warns of dangers if the
instructions are not heeded.
The sign is located behind the panelling at the
rear of the superstructure.
Abb. 27: Connecting hoses

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• Warning sign "Travel on slope". The
sign contains a work instruction.
The sign is attached near the control unit of
the manoeuvring drive.
Abb. 28: Travel on slope
• Sign "Activate manoeuvring drive".
The sign contains a work instruction.
The sign is attached near the control unit of
the manoeuvring drive.
Abb. 29: Activate manoeuvring drive
• Warning "Swivel range". The sign
warns of dangers if the instructions are
not heeded.
The sign is on the right of the structure.
Abb. 30: Swivel range
• Warning sign "Risk of stumbling over
supports; read operating
instructions, observe wind speed,
support unit and keep sufficient
distance to electrical power lines".
The sign warns of dangers if the
instructions are not heeded.
The sign is on the right of the structure.
Abb. 31: Warning

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• Specification of maximum permissible
tongue load.
The sign is mounted on the drawbar.
Abb. 32: Specification of tongue load
• Warning „Rivolta“. The sign warns of
dangers if the instructions are not
heeded.
The sign is mounted on the hydraulic oil tank.
Abb. 33: Hydraulic oil
• Warning sign "Risk of injury from
crushing of body parts".
The sign is attached near the wheels.
Abb. 34: Safety instructions regarding
crushing
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1.5 Liability and Guarantee
All information and instructions in this operating manual have been provided under due
consideration of applicable guidelines, the current state of engineering development, as well
as our many years of experience.
The actual scope of supply can vary from the explanations and graphic representations
provided in this manual in the case of special versions, if supplemental order options are
desired, or on the basis of the latest technical changes. Please contact the manufacturer if
there are questions.
NOTE!
This operating manual must be carefully read prior to starting all work on and with the
device, particularly prior to commissioning! Manufacturer assumes no liability for
damages and malfunctions due to failure to heed the instructions in the operating
manual.
We reserve the right to make changes to the product in the interest of enhancements and
improvement of the performance characteristics.
The German operating manual is binding. Translated versions are provided for information
purposes only.
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Components such as tools subject to normal wear and tear during the use of the device as
well as operating and process materials such as greases, oil or cleaning agents are not
covered by the warranty.
The obligations agreed upon in the supply contract, the terms and conditions, as well as the
manufacturer’s terms of delivery and all legal requirements applicable at the time of
conclusion of contract remain in full effect.
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1.6 Copyright
The operating manual should be treated confidentially. It has been exclusively prepared for
personnel working on and with the device. Making the operating manual accessible to third-
parties without written consent from the manufacturer is prohibited. If necessary, contact the
manufacturer.
Content information, text, drawings, graphics, and other representations are protected by
copyright and are subject to additional commercial property rights. Any improper use is
punishable.
Duplication in any form - including excerpts - as well as exploitation and/or communication of
the content are not permitted without a written declaration of release from the manufacturer.
Actions to the contrary make damage compensation mandatory. We reserve the right to
enforce additional claims.

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1.7 Spare parts
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ATTENTION!
Incorrect or defective replacement parts can cause damage, malfunction or total
device failure.
Only use the manufacturer's original replacement parts.
All guarantee claims, claims for service damages, and liability against the manufacturer, or
his authorized agents, dealers, or representatives are void if non-approved replacement
parts are used.
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1.8 Dismantling
For sorting, clean device and dismantle it in compliance with applicable industrial safety and
environmental protection guidelines.
WARNING!
Stored residual energy, sharp-edged components, points and corners on and in
the device, or on the necessary tools can cause serious injuries. Consequently
all dismantling work on the device should only be performed by qualified
personnel.
Prior to dismantling:
– Switch off device and safeguard it from being switched on again.
– Allow device to cool to ambient temperature.
– Physically disconnect the device from all energy supplies, discharge stored
residual energy in accordance with guidelines.
– Remove fuels and auxiliary substances ,as well as remaining processing
materials in an environmentally responsible manner.
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