Manitowoc Grove GMK 5250L Operating Instructions Manual
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Manitowoc Grove GMK 5250L Operating Instructions Manual

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Operating Instructions
3 302 633 en
27.09.2017

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Summary of Contents for Manitowoc Grove GMK 5250L

  • Page 1 Operating Instructions 3 302 633 en 27.09.2017...
  • Page 2 Important note Any type of duplication or excerpt from this document, even 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...
  • Page 3 Reduction of slewing speed – can be switched on and off In addition to the specifications in the lifting capacity table and operating manual supplied, the automatic reduction of the slewing speed can be switched off under certain conditions. Important notes These additional pages describe only this special function.
  • Page 4 Operation 1.2.1 Additional and modified operating elements In the Superstructure lock menu 1 The display switches to this position – was previously at position (2) – Operation 2 Slewing speed reduction on/off – Display 3 Reduction on – green 4 Reduction off – grey Menu-independent displays Warning messages on the RCL display –...
  • Page 5 1.2.2 Switching reduction off and on The reduction of the slewing speed is switched on with the ignition. Switching reduction off You can only switch off the reduction if the slewing range type Standard has been entered. • Select and confirm the symbol (2). –...
  • Page 6 Blank page 3 302 652 en Additional page GMK...
  • Page 7 Outrigger spans Overview metres (feet) / per cent The display RCL (1) shows the outrigger spans in metres (feet). The control units (2) indicate the outrigger spans in per cent. The percentage values in the enclosed lifting capacity table and the enclosed operating instruc- tions deviate from the percentage values actu- ally displayed on the control units (2) as they are based on different principles.
  • Page 8 GMK5150/GMK5150L Length specifications Percentages Lifting Control Overall widths Individual widths capacity unit table 7.600 m (24.9 ft) 3.800 m (12.5 ft) 100% 100% 6.700 m (22.0 ft) 3.350 m (11.0 ft) 5.900 m (19.4 ft) 2.950 m (9.7 ft) 5.100 m (16.7 ft) 2.550 m (8.4 ft) 2.500 m (8.2 ft) 1.250 m (4.1 ft)
  • Page 9 Telescoping emergency programe Return run of the telescoping cylinder In the Operating manual supplied, it is noted that special care must be taken when telescoping in the emergency programe (1), as no automatic monitoring takes place. If you move the telescoping cylinder without a telescopic section (return run), please also note all the information in these additional pages.
  • Page 10 Blank page 3 302 808 en Additional pages GMK...
  • Page 11 Crane cab heating and air-conditioning system Operation from the driver's cab In addition to the information given in the operating instructions supplied, the heating system and air-conditioning system in the crane cab can also be operated from the driver's cab. This enables, for example, the crane cab to be preheated while driving.
  • Page 12 Blank page 3 302 839 en Additional pages GMK...
  • Page 13 MAXbase Additional outrigger spans In addition to the information in the supplied Operating manual there are lifting capacity tables for further outrigger spans. These additional pages only show the additional outrigger spans. Outrigger span type Three / One Three outrigger beams are extended the same distance and one outrigger beam has a smaller outrigger span.
  • Page 14 Blank page 3 302 801 en-us Additional pages MAXbase...
  • Page 15 The operating instructions consist of the following chapters 1 Overview 2 Basic safety instructions 3 Operating elements for driving 4 Starting the engine for driving / switching it off 5 Driving 6 Driving modes and rigging for on-road driving 7 Malfunctions in driving mode 8 Operating elements for crane operation 9 Starting/switching off the engine –...
  • Page 16 Blank page 3 302 633 en Operating Instructions GMK5250L...

  • Page 17: Table Of Contents

    Manitowoc Crane Care ........
  • Page 18 3 302 633 en Operating Instructions GMK5250L...
  • Page 19 Basic safety instructions Intended use ............2 - 2.1.1 Improper use .
  • Page 20 3 302 633 en Operating Instructions GMK5250L...
  • Page 21 Operating elements for driving Overview of the operating elements ........3 - 3.1.1 Exterior of the truck crane .
  • Page 22 3.2.21 Front flap ............3 - 80 3 302 633 en Operating Instructions GMK5250L...
  • Page 23 Starting the engine for driving / switching it off Starting the engine from the driver's cab ....... . 4 - 4.1.1 CHECKLIST: Starting the engine .
  • Page 24 3 302 633 en Operating Instructions GMK5250L...
  • Page 25 Driving Before driving ............5 - 5.1.1 CHECKLIST: Checks before on-road driving.
  • Page 26 Towing a trailer ........... . 5 - 77 3 302 633 en Operating Instructions GMK5250L...
  • Page 27 Driving modes and rigging for on-road driving Driving modes ............6 - 6.1.1 How to use the tables .
  • Page 28 6.6.5 Lowering/raising the rigging frame........6 - 60 6.6.6 Placing the auxiliary hoist on the counterweight combination .
  • Page 29 Malfunctions in driving mode Emergency stop switch ..........7 - Procedure during malfunctions .
  • Page 30 3 302 633 en Operating Instructions GMK5250L...
  • Page 31 Operating elements for crane operation Overview of the operating elements ........8 - 8.1.1 Exterior of the truck crane .
  • Page 32 8.2.17 Slewing gear ........... . . 8 - 113 8.2.18 Derricking gear .
  • Page 33 Starting/switching off the engine – for crane operation When starting the engine for the first time in the day ..... 9 - 9.1.1 Checking the fuel level and AdBlue (DEF) level .
  • Page 34 3 302 633 en Operating Instructions GMK5250L...
  • Page 35 Crane operation 10.1 Before operating the crane ......... . . 10 - 10.1.1 CHECKLIST: Checks before operating the crane .
  • Page 36 10.6.1 Inclining the crane cab ..........10 - 121 10.6.2 Set idling speed .
  • Page 37 Rigging work 11.1 Rigging work checklists for crane operation with the main boom ..11 - 11.1.1 CHECKLIST: Rigging ..........11 - 11.1.2 CHECKLIST: Unrigging .
  • Page 38 11.9.3 Identification ........... . 11 - 71 11.9.4 Slinging points on the counterweight sections .
  • Page 39 Driving with a rigged truck crane 12.1 Driving path ............12 - 12.2 Permissible rigging modes and axle loads .
  • Page 40 3 302 633 en Operating Instructions GMK5250L...
  • Page 41 Transportation 13.1 Transport with transport vehicle ........13 - 13.1.1 CHECKLIST: Checks before transport .
  • Page 42 3 302 633 en Operating Instructions GMK5250L...
  • Page 43 Malfunctions during crane operation 14.1 Emergency stop switch..........14 - 14.2 What to do when malfunctions occur during crane operation .
  • Page 44 14.7.5 Performing emergency operation ........14 - 59 14.7.6 After emergency operation .
  • Page 45 Index Operating Instructions GMK5250L 3 302 633 en...
  • Page 46 3 302 633 en Operating Instructions GMK5250L...

  • Page 47: Overview

    In the case of an accident, contact the relevant branch office of in the country in which you are working and Manitowoc Crane Care specify your crane type and serial number. Adhere to the requirements regarding the obligation to report accidents prevalent in the country in which you are working and inform the supervi- sory authorities responsible for that particular type of accident (e.g.
  • Page 48 Overview 1.1 Accidents Blank page 1 - 2 3 302 633 en Operating Instructions GMK5250L...

  • Page 49: Branch Offices

    Overview 1.2 Branch offices Branch offices 1.2.1 Manitowoc Crane Care If you need help or support with the operation on your truck crane, you can contact our branches at the following addresses Manitowoc Crane Care http://www.manitowoccranes.com 1.2.2 Dealer list Visit the following address for a global list of dealers: http://www.manitowoccranes.com...

  • Page 50: Terms Used

    Overview 1.4 Terms used Terms used 1 - 4 3 302 633 en Operating Instructions GMK5250L...
  • Page 51 Overview 1.4 Terms used (A) – Carrier 1 Driver's cab 2 Boom rests 3 Counterweight platform 4 Axle lines 5 Outrigger beams 6 Outrigger cylinders 7 Outrigger pads (B) – Superstructure 8 Slewing gear 9 Crane cab 10 Main boom with telescoping mechanism 11 Telescopic sections 12 Hook block 13 Derricking cylinder, derricking gear...
  • Page 52 Overview 1.4 Terms used Blank page 1 - 6 3 302 633 en Operating Instructions GMK5250L...

  • Page 53: Technical Data

    Overview 1.5 Technical data Technical data GROVE crane GMK5250L Permissible temperature range: -25 °C to +40 °C (-13 °F to +104 °F) Crane designation: Truck crane to ISO 4306, parts 1 and 2 Crane classification: Crane class A1 to ISO 4301, Part 2 The crane is designed to crane class A1 (as defined in ISO standard 4301 - 2).

  • Page 54: Dimensions And Weights Of The Truck Crane, Axle Loads

    Overview 1.5 Technical data 1.5.3 Dimensions and weights of the truck crane, axle loads All dimensions in the illustration are in mm. 1 - 8 3 302 633 en Operating Instructions GMK5250L...
  • Page 55 Overview 1.5 Technical data à Driving modes , p. 6 - 1. Dimensions All dimensions relate to on-road mode; Length without auxiliary 15.29 m (50.2 ft) hoist: Height: At on-road level: – 385/95 R25 3.94 m (12.9 ft) – 445/95 R25 3.99 m (13.1 ft) –...

  • Page 56: Dimensions And Weights Of Removable Parts

    Overview 1.5 Technical data 1.5.4 Dimensions and weights of removable parts This section contains the dimensions and weights of the parts which can be à Driving modes , p. 6 - 1. removed for on-road driving; Spare wheel Length x width x height Weight in kg Designation in m (ft)
  • Page 57 Overview 1.5 Technical data Main boom Designation Length x width x Weight in kg (lbs) height in m (ft) Complete main boom 13.85 x 1.50 x 2.00 21,000 (45.44 x 4.9 x 6.6) (46,300) Hook blocks and hook tackle Length x width x height Weight Designation...
  • Page 58 Overview 1.5 Technical data Hook blocks, split Dimensions (m) (ft) and weights (kg) (lbs) 1.98 0.90 1.20 1.98 0.90 1.30 Length (6.50) (2.95) (3.94) (6.50) (2.95) (4.27) 0.70 0.70 0.70 0.70 0.70 0.70 Width (2.30) (2.30) (2.30) (2.30) (2.30) (2.30) 0.76 0.32 0.76...
  • Page 59 Overview 1.5 Technical data Auxiliary hoist Length x width x height Weight Designation in m (ft) in kg (lbs) Complete auxiliary hoist 1.15 x 1.90 x 0.80 2,000 (4,410) (3.77 x 6.23 x 2.62) Rigging frame 1.43 x 2.17 x 0.55 (776) (4.69 x 7.12 x 1.80) Counterweight...
  • Page 60 Overview 1.5 Technical data Blank page 1 - 14 3 302 633 en Operating Instructions GMK5250L...

  • Page 61: Carrier

    Overview 1.5 Technical data 1.5.5 Carrier Engine Mercedes-Benz: OM 471 LA Engine emissions: 97/68/EC Level 4 (TIER 4 Final/Euromot 4) Power: 390 kW (530 PS) at 1,700 rpm (80/1269 - 89/491 EWG, – including all modifications) Fuel tank: 1 x approx. 400 l (105 gal) and 1 x approx. 300 l (79 gal) AdBlue tank: approx.
  • Page 62 Overview 1.5 Technical data Tyres 10 x 385/95 R 25 on disc wheels 9.50-25/1.7 10 x 445/95 R 25 on disc wheels 11.00-25/1.7 10 x 525/80 R 25 on disc wheels 17.00-25/1.7 Additional equipment Torque for wheel nuts: 650 Nm (480 lbf ft). Tyre pressure with cold tyres for axle loads up to max.
  • Page 63 Overview 1.5 Technical data Outrigger Design: 4-point telescoping outrigger system Control system: Can be controlled from both sides on the carrier and individually from the crane cab Outrigger spans: 8.950x 7.800 m (29.4 x 25.6 ft) 8.950 x 6.854 m (29.4 x 22.4 ft) 8.950 x 5.910 m (29.4 x 19.4 ft) 8.950 x 4.310 m (29.4 x 14.2 ft) 8.950 x 2.710 m (29.4 x 8.8 ft)
  • Page 64 Overview 1.5 Technical data Turning radii All dimensions in the illustration are in mm. = values for normal steering mode = values for all-wheel steering 1 - 18 3 302 633 en Operating Instructions GMK5250L...

  • Page 65: Superstructure

    Overview 1.5 Technical data 1.5.6 Superstructure Main hoist Drum diameter: 458 mm (18 in) (rope centre to rope centre) Rope diameter: 22 mm (0.87 in) Rope length: 330 m (1,082 ft) Rope pull: 93.5 kN (23,380 lbf) Power unit group: M 5 (to ISO 4301 - 2) Load spectrum: Factor of the load spectrum Km = 0.125...
  • Page 66 Overview 1.5 Technical data Derricking gear Cylinder: Differential cylinder Adjusting angle -1.5° to + 82° from horizontal position (main boom): Power unit group M2 (to ISO 4301 - 2) Main boom Main boom lengths: 13.3 m to 70.0 m (43.5 ft to 229.7 ft) Main boom head: 7 sheaves or 10 sheaves Cylinder:...
  • Page 67 Overview 1.5 Technical data Operating speeds The specified operating speeds only apply to an engine speed of about 1,190 rpm without load. Main hoist: Rope speed when lifting and lowering Normal speed: Maximum 60 m/min (197 ft/min) High-speed Maximum 120 m/min (394 ft/min) mode: Auxiliary hoist: Rope speed when lifting and lowering...
  • Page 68 Overview 1.5 Technical data Blank page 1 - 22 3 302 633 en Operating Instructions GMK5250L...

  • Page 69: Documentation Supplied

    – Documents from other manufacturers Original documentation for parts not manufactured by Manitowoc Crane , such as the engine and central lubrication system, Group Germany GmbH as well as the tachograph, auxiliary heaters, radio and, where appropri- ate, other additional equipment.

  • Page 70: Questions On Documentation

    Dealer list , p. 1 - 3. You can find your responsible dealer here: You can also send questions in either German or English directly to: Email: whv-techpublications@manitowoc.com For repeat orders for documentation, please contact our EMEA service. 1 - 24...

  • Page 71: Notes On The Operating Manual

    Overview 1.7 Notes on the operating manual Notes on the operating manual This operating manual is not a training manual for prospective crane oper- ators! All descriptions are written explicitly for crane operators who have been trained to operate truck cranes! This operating manual is designed as a reference manual.
  • Page 72 Overview 1.7 Notes on the operating manual This symbol indicates dangers which represent a hazard to objects, e.g. damage to the truck crane or other parts which are located within the working range. This symbol alerts you to situations where there is a risk of receiving an electric shock.

  • Page 73: How Is The Operating Manual Structured

    Overview 1.7 Notes on the operating manual 1.7.2 How is the operating manual structured? Division – The chapters 1 to 7 contain a description of how to drive the truck crane. – The chapters 8 to 15 contain a description of crane operation. The complete operating manual must always be carried in the truck crane.
  • Page 74 Overview 1.7 Notes on the operating manual Structure of Each page in the operating manual is divided into a wide text column and a the pages narrow column. The narrow column contains various pieces of information: – Chapter and section numbers, –...

  • Page 75: How Do I Find The Information I Need

    Overview 1.7 Notes on the operating manual 1.7.3 How do I find the information I need? The operating manual contains the following guides for orientation. – The Contents lists all chapters in the operating instructions. – The Table of contents provides an overview of the topics. –...
  • Page 76 Overview 1.7 Notes on the operating manual Cross-references The illustrations and texts in this section are only an example and may differ example from the conditions on your truck crane. 1 - 30 3 302 633 en Operating Instructions GMK5250L...
  • Page 77 Overview 1.7 Notes on the operating manual The parking brake is used as an example to show how the cross-references guide you through the operating manual. A In this example, the general overview is shown on page 3 - 2. The driver's cab is labelled as number 1.

  • Page 78: What Information Is Available For Operations Planning

    Overview 1.7 Notes on the operating manual 1.7.4 What information is available for operations planning? Extensive information is required for operations planning in order to guarantee safe, smooth and efficient operation of the truck crane: The operating manual contains à –...

  • Page 79: Conversion Table For Us Measuring Units

    Overview 1.8 Conversion table for US measuring units Conversion table for US measuring units The following conversion factors will help you convert from metric to US units when the truck crane is used in countries that use US units of measurement and vice versa.
  • Page 80 Overview 1.8 Conversion table for US measuring units Blank page 1 - 34 3 302 633 en Operating Instructions GMK5250L...

  • Page 81: Training - Information

    1.9 Training – Information Training – Information For the EMEA area (Europe, Middle East, Africa), Manitowoc Crane Group offers comprehensive training for crane types GMK and GTK. Germany GmbH Our training centre is located in a maritime environment, on Germany's North Sea coast at Wilhelmshaven.

  • Page 82: Identification

    Overview 1.10 Identification 1.10 Identification 1 - 36 3 302 633 en Operating Instructions GMK5250L...
  • Page 83 Overview 1.10 Identification The following plates and numbers are attached to the truck crane for identification purposes: 1 Serial number and crane type 2 The CE mark, only with truck cranes that are delivered in member countries of the EU. 3 The serial number of the driver's cab 4 The chassis number and crane type 5 The chassis number in front of the first axle line in the frame.

  • Page 84: Ec Declaration Of Conformity

    Overview 1.11 EC Declaration of Conformity 1.11 EC Declaration of Conformity On initial delivery, operators of truck cranes receive a Declaration of Conformity as a sup- plement to the delivery protocol. An illustra- tion of the Declaration of Conformity is shown below.

  • Page 85: Basic Safety Instructions

    The GMK5250L may only be operated with parts of equipment which have been approved by and which are Manitowoc Crane Group Germany GmbH labelled with the serial number of the GMK5250L. The manufacturer is not liable for any damage caused by improper or unau- thorized use of the GMK5250L truck crane.

  • Page 86: Improper Use

    2.1 Intended use 2.1.1 Improper use is not liable for damage resulting Manitowoc Crane Group Germany GmbH from improper or unauthorized use of the GMK5250L truck crane. The user shall take on full responsibility for any such use. Improper use includes: –...

  • Page 87: Organisational Measures

    Basic safety instructions 2.2 Organisational measures Organisational measures The operating manual and the lifting capacity table should be kept in the truck crane for immediate access at all times, and must not be removed from the truck crane. You must have read and understood the operation and safety instructions in this operating manual and comply with them when working.
  • Page 88 All welding work (especially on load carrying members) may only be performed by properly qualified personnel with the prior permission of Manitowoc Crane Group Germany GmbH To avoid damage, especially to electronic parts, there are certain measures you must take before doing any welding work. You should therefore, always consult before performing any welding work.

  • Page 89: Personnel Qualifications

    Basic safety instructions 2.3 Personnel qualifications Appropriate servicing equipment is absolutely necessary in order to carry out maintenance work. Observe national regulations that apply to transport when loading the truck crane. Also observe the additional safety measures prescribed by the for- warder (e.g.

  • Page 90: Safety Instructions For Driving The Truck Crane

    Manitowoc Crane Group Germany GmbH crane operator courses and technical courses. Safety instructions for driving the truck crane Walk around and inspect the truck crane before you start the vehicle. Check the condition of the truck crane carefully using the checklists in the operat- ing manual.

  • Page 91: Safety Instructions For Crane Operation

    Basic safety instructions 2.5 Safety instructions for crane operation Check all operating and control elements in the driver's cab before starting the engine. After starting the engine, take note of all the lights and control elements. After driving, secure the truck crane against unauthorised use. Safety instructions for crane operation Carefully select a safe site for the truck crane, where you can work safely.
  • Page 92 Basic safety instructions 2.5 Safety instructions for crane operation If necessary, remove any ice and snow from the truck crane before com- mencing crane operation. Keep all handles, steps, step treads and ladders free of dirt, snow and ice. Keep all electric and hydraulic connections free of dirt. Check the connecting points for dust, foreign bodies and moisture before installation.
  • Page 93 If locally applicable national regulations require the truck crane to be tested by lifting an exces- sively heavy load (overload test), always first consult Manitowoc Crane Care Operating Instructions GMK5250L 3 302 633 en...

  • Page 94: Instructions On Transporting Persons

    Basic safety instructions 2.6 Instructions on transporting persons Instructions on transporting persons The truck crane is intended for lifting loads. Transporting persons is consid- ered improper use of the truck crane. It is prohibited to: – transport persons in any way with the lifting tackle or on the load. –...
  • Page 95 Basic safety instructions 2.6 Instructions on transporting persons The crane operator must have knowledge of and meet the requirements of the relevant legal regulations and standards (e.g. the BGR 159 in Germany or the ASME B30 in the USA). The crane operator must have the necessary knowledge for operating the truck crane and the equipment used for lifting persons.
  • Page 96 Basic safety instructions 2.6 Instructions on transporting persons The person being transported must be in radio contact with the crane operator. When used for transporting persons, the truck crane must not be used for other tasks. The crane operator is not permitted to exceed the maximum permissible wind speeds and wind loads for transporting persons applicable in the country in which he is working.

  • Page 97: Operating Elements For Driving

    Operating elements for driving 3.1 Overview of the operating elements Operating elements for driving All operating elements for crane operation are described in Chapter 8. Overview of the operating elements This section shows the position and designation of the operating elements for driving.

  • Page 98: Exterior Of The Truck Crane

    Operating elements for driving 3.1 Overview of the operating elements 3.1.1 Exterior of the truck crane 3 - 2 3 302 633 en Operating Instructions GMK5250L...
  • Page 99 Operating elements for driving 3.1 Overview of the operating elements à 1 Front flap p. 3 - 80 à 2 Driver's cab p. 3 - 6 3 Hose drum à 4 Rigging the main boom p. 6 - 15 à 5 Ladders p.
  • Page 100 Operating elements for driving 3.1 Overview of the operating elements 3 - 4 3 302 633 en Operating Instructions GMK5250L...
  • Page 101 Operating elements for driving 3.1 Overview of the operating elements à 19 External starting socket p. 7 - 25 à Connection for battery charger p. 7 - 25 à 20 Adjusting the mirrors p. 5 - 7 à 21 Switching on the boom floating position p.

  • Page 102: Driver's Cab

    Operating elements for driving 3.1 Overview of the operating elements 3.1.2 Driver's cab Overview 3 - 6 3 302 633 en Operating Instructions GMK5250L...

  • Page 103: 10 Steering Column/Steering Wheel

    Operating elements for driving 3.1 Overview of the operating elements à 1 Passenger's seat p. 5 - 13 2 Storage or 2nd passenger seat 3 Fire extinguisher à 4 Instrument panel, left/right p. 3 - 13 à 5 Parking brake p.
  • Page 104 Operating elements for driving 3.1 Overview of the operating elements 3 - 8 3 302 633 en Operating Instructions GMK5250L...
  • Page 105 Operating elements for driving 3.1 Overview of the operating elements 1), 2) 20 Radio à 21 BirdView-System 270°– monitor p. 3 - 57 à 22 Heating/Air-conditioning system p. 3 - 20 à 23 CCS control unit p. 3 - 24 à...
  • Page 106 Operating elements for driving 3.1 Overview of the operating elements Behind the cover à 1 Fuses p. 7 - 37 In the rear of the driver's cab 1 Spare key, radio accessories 2 Storage compartment (e.g. for hand-held control, battery charger) 3 - 10 3 302 633 en Operating Instructions GMK5250L...
  • Page 107 Operating elements for driving 3.1 Overview of the operating elements 3.1.3 Steering column/steering wheel à 1 Operating the on-board computer p. 3 - 76 2 Operation: à – Set idling speed p. 3 - 46 à – Setting the Tempomat p.
  • Page 108 Operating elements for driving 3.1 Overview of the operating elements Blank page 3 - 12 3 302 633 en Operating Instructions GMK5250L...

  • Page 109: Instrument Panel

    Operating elements for driving 3.1 Overview of the operating elements 3.1.4 Instrument panel Left/right à 1 Lighting on/off p. 3 - 69 à 2 Rotating beacons on/off p. 3 - 70 à 3 Battery master switch p. 4 - 11 à...
  • Page 110 Operating elements for driving 3.1 Overview of the operating elements Middle 3 - 14 3 302 633 en Operating Instructions GMK5250L...
  • Page 111 Operating elements for driving 3.1 Overview of the operating elements à 1 Indicator lamp for turn signal indicator p. 3 - 69 à 2 Indicator lamp for trailer turn signal indicator p. 3 - 69 à 3 Speedometer p. 3 - 74 à...
  • Page 112 Operating elements for driving 3.1 Overview of the operating elements On-board compu- ter time correction à 1 Time correction –: p. 3 - 76 à 2 Time correction +: p. 3 - 76 3 - 16 3 302 633 en Operating Instructions GMK5250L...

  • Page 113: Transmission Operating Elements

    Operating elements for driving 3.1 Overview of the operating elements 3.1.5 Transmission operating elements à 1 Selecting the driving direction p. 3 - 53 à 2 Changing the operating mode p. 3 - 53 à 3 Shift down, manual p. 3 - 53 à...

  • Page 114: On-Board Computer

    Operating elements for driving 3.1 Overview of the operating elements 3.1.6 On-board computer à 1 Main menu display p. 3 - 76 à 2 Display menu – Name p. 3 - 76 à 3 Submenu display p. 3 - 76 à...

  • Page 115: Tachograph

    Operating elements for driving 3.1 Overview of the operating elements 3.1.7 Tachograph (A) – Tachograph à 1 Display p. 5 - 20 à 2 Time correction –: p. 3 - 74 à 3 Time correction +: p. 3 - 74 à...

  • Page 116: Heating/Air-Conditioning System

    Operating elements for driving 3.1 Overview of the operating elements 3.1.8 Heating/Air-conditioning system Standard heating system à 1 Setting the blower/fresh air/recirculated air p. 5 - 63 à 2 Air distribution p. 5 - 64 à 3 Setting the temperature p.
  • Page 117 Operating elements for driving 3.1 Overview of the operating elements Auxiliary water heating system à 1 Heating display p. 5 - 71 à 2 Setting time and weekday p. 5 - 71 à 3 – Saving automatic heating start p. 5 - 72 à...
  • Page 118 Operating elements for driving 3.1 Overview of the operating elements Blank page 3 - 22 3 302 633 en Operating Instructions GMK5250L...
  • Page 119 Operating elements for driving 3.1 Overview of the operating elements Auxiliary air heater à 1 Heating display p. 5 - 75 à 2 Temperature p. 5 - 76 à 3 Setting the time/day p. 5 - 76 à 4 – Storing the heating start p.

  • Page 120: Ccs Control Unit

    Operating elements for driving 3.1 Overview of the operating elements 3.1.9 CCS control unit 3 - 24 3 302 633 en Operating Instructions GMK5250L...
  • Page 121 Operating elements for driving 3.1 Overview of the operating elements à 1 CCS display p. 3 - 51 à Overview start menu p. 3 - 27 à 2 Service/diagnostics connection p. 3 - 75 à 3 Exiting the menu/input mode p.

  • Page 122: Ccs - Menu-Dependent Displays

    Operating elements for driving 3.1 Overview of the operating elements 3.1.10 CCS – menu-dependent displays à 1 Transverse differential locks display p. 3 - 59 à Longitudinal differential lock display p. 3 - 60 à 2 Display of retarder function on/off p.

  • Page 123: Ccs - Start Menu

    Operating elements for driving 3.1 Overview of the operating elements 3.1.11 CCS – Start menu 1 Display of crane type à 2 Display time p. 3 - 34 à 3 Display of transverse and longitudinal differential p. 3 - 32 locks on/off à...

  • Page 124: Ccs - Overview Menu Groups

    Operating elements for driving 3.1 Overview of the operating elements 3.1.12 CCS – Overview menu groups 3 - 28 3 302 633 en Operating Instructions GMK5250L...
  • Page 125 Operating elements for driving 3.1 Overview of the operating elements à 1 Carrier menu group p. 3 - 30 – Suspension/ level adjustment menu – Driving menu à 2 Settings menu group p. 3 - 33 – Set display brightness and date/time menu à...

  • Page 126: Carrier Menu Group

    Operating elements for driving 3.1 Overview of the operating elements 3.1.13 Carrier menu group à 1 Suspension/ level adjustment menu p. 3 - 31 à 2 Driving menu p. 3 - 32 3 - 30 3 302 633 en Operating Instructions GMK5250L...
  • Page 127 Operating elements for driving 3.1 Overview of the operating elements Suspension/ level adjustment menu à 1 Front level pre-selection p. 3 - 72 à 2 Lowering/raising the level p. 3 - 72 à 3 Current inclination display p. 3 - 67 à...
  • Page 128 Operating elements for driving 3.1 Overview of the operating elements Driving menu à 1 Current wheel position display p. 3 - 66 à 2 Steering locking status display p. 3 - 66 à 3 Transverse differential locks display p. 3 - 59 à...

  • Page 129: Settings Menu Group

    Operating elements for driving 3.1 Overview of the operating elements 3.1.14 Settings menu group à 1 Set display brightness and date/time menu p. 3 - 34 Operating Instructions GMK5250L 3 302 633 en 3 - 33...
  • Page 130 Operating elements for driving 3.1 Overview of the operating elements Set display bright- ness and date/ time menu à 1 Selection setting the display brightness p. 4 - 13 à 2 Increasing/reducing the value p. 4 - 13 à 3 Display in percentage p.

  • Page 131: Information Menu Group

    Operating elements for driving 3.1 Overview of the operating elements 3.1.15 Information menu group à 1 Operating hours menu p. 3 - 36 à 2 Engine/transmission error menu p. 3 - 37 à 3 Crane operation error menu p. 3 - 38 Operating Instructions GMK5250L 3 302 633 en 3 - 35...
  • Page 132 Operating elements for driving 3.1 Overview of the operating elements Operating hours menu 1 Keycode input 2 Carrier à 3 Engine p. 5 - 23 4 Transmission 5 Selection all 3 - 36 3 302 633 en Operating Instructions GMK5250L...
  • Page 133 Operating elements for driving 3.1 Overview of the operating elements Engine/transmis- sion error menu 1 Display of error / total errors 2 Engine symbol display 3 Transmission symbol display à p. 7 - 15 4 Error code display 5 Previous error 6 Next error Operating Instructions GMK5250L 3 302 633 en...
  • Page 134 Operating elements for driving 3.1 Overview of the operating elements Crane operation error menu 1 Current errors/total errors display 2 Error code 3 Deleting errors 4 Previous error 5 Next error Since this menu is required for crane operation, it is described in the chapter à...

  • Page 135: Various Controls Menu Group

    Operating elements for driving 3.1 Overview of the operating elements 3.1.16 Various controls menu group à 1 Spotlights on rear of carrier on/off p. 3 - 70 à 2 Reverse camera on/off p. 3 - 56 3.1.17 Emergency operations menu group à...

  • Page 136: Outrigger Control Units

    Operating elements for driving 3.1 Overview of the operating elements 3.1.18 Outrigger control units à Outrigger control units , Contains operating elements for crane operation; p. 8 - 79. 3 - 40 3 302 633 en Operating Instructions GMK5250L...

  • Page 137: Sockets For Hand-Held Control

    Operating elements for driving 3.1 Overview of the operating elements 3.1.19 Sockets for hand-held control There are sockets (4) on the carrier and sockets (1) to (3) on the superstruc- ture for the hand-held controls supplied. The hand-held controls contain the operating elements for the outrigger, the inclination indicator, for rigging work and for driving the power units in case of emergency.
  • Page 138 Operating elements for driving 3.1 Overview of the operating elements Blank page 3 - 42 3 302 633 en Operating Instructions GMK5250L...

  • Page 139: Brief Description Of The Operating Elements

    This section does not contain all the requirements that must be fulfilled for several operating elements to be active. If some operating elements do not work, first read the following chapters referred to at the respective places before contacting Manitowoc Crane Care Operating Instructions GMK5250L 3 302 633 en 3 - 43...

  • Page 140: Definition Of Direction Information

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.1 Definition of direction information Basic rule Direction information always depends on whether the carrier or the super- structure is being operated. On the carrier The driver's cab is always at the front, which means that: 1: Front 2: Right 3: Rear...

  • Page 141: General Rules For Buttons And Symbols On The Display

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.2 General rules for buttons and symbols on the display The symbols shown as an example are not present on all crane types. The following rules apply in all menus: –...

  • Page 142: Engine

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.3 Engine Steering column Ignition lock 0 Ignition off, engine off, key can be removed 1 Power supply on for: Heating system, engine/transmission diagnostics, radio/telephone, enabling of steering lock 2 Ignition on, driving position, daytime driving light on 3 Starting position à...
  • Page 143 Operating elements for driving 3.2 Brief description of the operating elements Setting the Tempomat The truck crane must be driving at a speed at least 15 km/h (9 mph). 2 Select the Cruise control menu – symbol (1) is grey 3 Switches on or increases the speed –...

  • Page 144: Adblue System (Def)

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.4 AdBlue system (DEF) Instrument panel AdBlue warning – Off: Filling level sufficient, no fault – On: AdBlue system malfunction – Flashing: Adblue tank empty or fault à p. 5 - 45 Torque reduction indicator –...

  • Page 145: Battery Master Switch

    Operating elements for driving 3.2 Brief description of the operating elements CCS display Adblue filling level monitoring submenu – Display Green: Over 10% – over 4 l (0.9 gal) Yellow: 5 to 10% – 2 to 4 l (0.4 to 0.9 gal) Red: Below 5% –...

  • Page 146: Electrical System

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.6 Electrical system 12 V power socket on/off – To switch on: Press switch (1) in at the top – To switch off: Press switch (1) in at the bottom Sockets 12 V/24 V 1 Socket 12 V/max.

  • Page 147: Ccs Crane Control

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.7 CCS Crane control The GMK5250L truck crane is equipped with the CCS electronic crane con- trol system (Crane Control System). CCS includes a control unit in the driver's cab and several control units (MWSCM and MWCCM) distributed over the superstructure and carrier.
  • Page 148 Operating elements for driving 3.2 Brief description of the operating elements Exiting the menu/input mode 1 Press: – The opened menu closes – the menu from the next higher level is opened. – Input mode is deactivated. Overview menu groups 1 Press: –...

  • Page 149: Transmission

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.8 Transmission à Operating the transmission , p. 5 - 25. Transmission Selecting the transmission mode control unit The engine must be running. – Position N: Select neutral – No gear engaged –...
  • Page 150 Operating elements for driving 3.2 Brief description of the operating elements Driving mode display Transmission display 1 Currently engaged gear – forwards (1 to 16), e.g. 6 2 Neutral position switched on 3 Gear currently engaged – 1st reverse gear 4 Gear currently engaged –...
  • Page 151 Operating elements for driving 3.2 Brief description of the operating elements Shifting lever The truck crane may be stationary or driving. – Press in once: Change over between automatic and manual operating mode – without change of gear à p. 5 - 29 The truck crane is stationary.

  • Page 152: Reverse Camera

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.9 Reverse camera The reverse camera (1) displays the area behind the truck crane on the CCS display in the driver's cab. • Switch on the spotlight if necessary. Switching on –...

  • Page 153: Birdview System 270

    Drive with due care and attention! The sole responsibility lies with the crane operator. explicitly states that no liability is Manitowoc Crane Group Germany GmbH accepted for damage resulting from a failure to observe these instructions. Risk of damage in driving mode! Obstacles in the driving area above the height of the camera are not dis- played.
  • Page 154 Operating elements for driving 3.2 Brief description of the operating elements The cameras must not be removed or misadjusted. If a camera is mounted on the storage box then the storage box must not be removed. There may be no spare wheel installed on the rear of carrier. Switching on •...

  • Page 155: Final Drive

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.11 Final drive à Longitudinal and transverse differential locks , p. 5 - 50 Driving menu To open: Select symbol (1) and confirm – menu is opened Transverse differential locks on/off –...
  • Page 156 Operating elements for driving 3.2 Brief description of the operating elements Longitudinal differential lock on/off – To switch on: Select symbol (1) and confirm – symbol is red – To switch off: Select symbol (1) and confirm – symbol is green Longitudinal differential lock display The current status is shown using different symbols:...

  • Page 157: Brakes

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.12 Brakes Service brake Display of supply pressure in brake circuits 1 Current supply pressure in brake circuit 1 2 Current supply pressure in brake circuit 2 3 red – supply pressure insufficient white –...
  • Page 158 Operating elements for driving 3.2 Brief description of the operating elements Instrument panel Additional brake indicator lamp – On: Additional brake on – Off: Additional brake off – Flashing: – Ignition on – Multipurpose switch not in position 0 – Engine is running – retarder power reduced Parking brake Parking brake indicator lamp –...
  • Page 159 Operating elements for driving 3.2 Brief description of the operating elements 1 To engage the Pull the lever down until it locks into place parking brake: 2 To release the Lift the lever and push it up until it latches into parking brake: place 3 To operate as an...

  • Page 160: Steering / Separate Steering

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.13 Steering / separate steering à Separate steering , p. 5 - 59 Instrument panel Steering circuit 1 and 2 warning lamp – On: Engine off – ignition on Engine on –...
  • Page 161 Operating elements for driving 3.2 Brief description of the operating elements Steering system warning – On: Steering system faulty – stop immediately, Display symbol (1) – 4th and 5th axle cannot be steered; if it is possible, it can only be steered in straight running position –...
  • Page 162 Operating elements for driving 3.2 Brief description of the operating elements Steering locking status display The current status is shown using different symbols: 1 green – locked 2 red – unlocked 3 yellow – intermediate position 4 Error Current wheel position display The current status is shown using different symbols: 1 Straight ahead...

  • Page 163: Suspension

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.14 Suspension à Switching the suspension on/off , p. 5 - 15. CCS display Suspension on/off – Switch on: Select symbol (1) and confirm – Symbol (2) green (on-road driving) –...

  • Page 164: Lighting/Windscreen Wipers/Horn

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.15 Lighting/windscreen wipers/horn Steering column Multipurpose switch Headlight flasher/full beam headlight 1 Parking light/headlight: Mid-position 2 Flash the headlights: Upwards The parking light/headlight must be switched on: 3 Headlight – full-beam: Down –...
  • Page 165 Operating elements for driving 3.2 Brief description of the operating elements Indicator lamp for turn signal indicator 1 – Flashing: Turn signal indicator on – Off: Turn signal indicator off, or turn signal indicator on and filament lamp faulty Indicator lamp for trailer turn signal indicator 1 –...
  • Page 166 Operating elements for driving 3.2 Brief description of the operating elements Headlight check – On: Headlight on – Off: Headlight off Rotating beacons on/off – To switch on: Push up – To switch off: Push down Outrigger lighting on/off – To switch on: Push up –...
  • Page 167 Operating elements for driving 3.2 Brief description of the operating elements Roof The lamps on the driver's and passenger side are identical. Cab lighting 1 Always on 2 Always off 3 On/off via door contact Reading lamp 1 On 2 Off Operating Instructions GMK5250L 3 302 633 en 3 - 71...

  • Page 168: Level Adjustment System

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.16 Level adjustment system à Operating the level adjustment system , p. 5 - 52. Suspension/level adjustment menu – To open: Select symbol (1) and confirm – menu is opened Lift/lower preselection level The suspension is switched on Select and confirm the corresponding symbol.
  • Page 169 Operating elements for driving 3.2 Brief description of the operating elements Setting the on-road level The suspension is switched on. 1 Select and confirm – level is changed until the on-road driving level is reached. 2 On-road driving level reached à...

  • Page 170: Tachograph/Speedometer

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.17 Tachograph/speedometer à Setting the tachograph , p. 5 - 17. Tachograph Time correction occurs for both the Tachograph and on-board computer 1 Open the time menu: Press the button – the time correction menu opens 2 Time correction +: Press the button –...

  • Page 171: Diagnostics

    Diagnostics The diagnostics connections (1) may only be operated by service staff from the engine and transmission manufacturer, or by Manitowoc Crane Care Additional diagnostic and service connections are present on the CCS control unit (2). • Do not connect external devices, e.g. a...

  • Page 172: On-Board Computer

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.19 On-board computer Click here for more information on the on-board computer menus. Operating the on-board computer On the steering wheel: 1 Previous menu window, menu entry upwards 2 Next main menu, select next entry, increase or reset value 3 Next menu window, one menu entry downwards...
  • Page 173 Operating elements for driving 3.2 Brief description of the operating elements Tour data menu 1 Total mileage 2 Daily mileage 3 Time 4 Outside temperature Operating Instructions GMK5250L 3 302 633 en 3 - 77...

  • Page 174: Windows, Doors, Keys

    Operating elements for driving 3.2 Brief description of the operating elements 3.2.20 Windows, doors, keys Window winder The windows stop moving when the window winders encounter resistance. Button assignment A Window winder, driver's door B Window winder, passenger door 1 To open the window 2 To close the window Movement stops after the button is released and when an end position is reached.
  • Page 175 Operating elements for driving 3.2 Brief description of the operating elements Doors The same key is used for the driver's and passenger door. Always take the ignition key with you before closing the door from outside with the handle pressed in (2). Once closed in this manner, the door can only be opened again using the ignition key.
  • Page 176 Operating elements for driving 3.2 Brief description of the operating elements 3.2.21 Front flap Opening • Move the front flap (1) up as far as it will go, holding it by the upper edge. The front flap is held in the open position. Closing •...

  • Page 177: Starting The Engine For Driving / Switching It Off

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab Starting the engine for driving / switching it off Starting the engine from the driver's cab This section describes how to start the engine from within the driver's cab. You can also start the engine using the hand-held control, or from the crane à...
  • Page 178 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab à 4. Switch on the battery master switch; p. 4 - 11. 5. Check that – The bridging plugs are inserted in the sockets for hand-held control; à...
  • Page 179 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 10. Check the consumable reserve; à Standard tank , p. 4 - 7, – à AdBlue , p. 4 - 9. – à 11.

  • Page 180: Checklist: At Low Temperatures

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.2 CHECKLIST: At low temperatures You must also observe the following points when operating the truck crane at low outside temperatures: 1. The fuel and engine oil must be suited for use in the outside tempera- à...
  • Page 181 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab Ladders There are different ladders on the truck crane. Risk posed by ladders falling down! Always secure the ladders before driving. The prevents the ladders from falling down while driving and endangering other vehicles.
  • Page 182 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab There is an additional ladder on the carrier. You can fold the ladder (1) out and in. Securing for driving • Push the ladder (4) under the clamp (1). •...

  • Page 183: Filling Up

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.4 Filling up à Separate engine operating instructions, Only use permissible consumables; provided by the manufacturer . Danger of fire due to flammable gases! Switch off the engine, the heater and all additional heaters before refuelling.
  • Page 184 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab Dual tank The dual tank system makes it possible to operate the truck crane in driving mode and crane operation mode with different types of fuel, provided this complies with the local regulations in the country in which you are working.
  • Page 185 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab AdBlue The displays (2) and (3) indicate the current fill- ing level. The level indicator (3) changes colour depend- ing on the fill level: Green: Over 10% –...

  • Page 186: Checks Before Starting The Engine

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.5 Checks before starting the engine At the hydraulic Before you start the engine, all valves on the hydraulic tank must be open. tank Risk of damage to the hydraulic pumps! You may only start the engine when all the valves on the hydraulic tank are...

  • Page 187: Switch On The Ignition

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab Battery master You can only start the engine when the battery master switch is switched switch • Switch on the battery master switch (1). Checking the Check that the hand-held control has been removed, and that bridging plugs à...

  • Page 188: Lamp Test/Equalisation Of The Switching States

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.7 Lamp test/equalisation of the switching states Lamp test After the ignition has been switched on, a lamp test is performed. Risk of accidents due to faulty lamps! The lamps that are used to provide warnings and information during oper- ation light up for control purposes whenever the ignition is switched on.

  • Page 189: Display - Setting The Brightness

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.8 Display – setting the brightness The brightness of the displays is regulated automatically by the CCS , depending on the ambient brightness. You can set a minimum degree of brightness manually, which is always observed when the brightness is regulated.

  • Page 190: Start The Engine

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.9 Start the engine This section describes only how to start the engine from the driver's cab. You can also start the engine: à...
  • Page 191 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab This section relates to starting a warm and cold engine. Danger of explosion when using starter fuel! The engine may never be started with the aid of starter fuel. Starter fuel sprayed into the suction unit can ignite.

  • Page 192: Inspections After Starting The Engine

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.10 Inspections after starting the engine Start menu and on-board computer Risk of damage to the engine! If a symbol is displayed in the display area (1) or the on-board computer display (2) and the warning buzzer sounds then switch off the engine imme- diately.
  • Page 193 When the symbol (2) The oil supply for the steering is still being built is displayed: up. If the symbol has not yet gone out, contact Manitowoc Crane Care When the symbol (3) Service mode on. is displayed: Briefly switch the ignition off and then on again.
  • Page 194 You must not under any circumstances drive the truck crane. Contact and arrange for the error to be rectified. Manitowoc Crane Care Risk of accidents because the truck crane cannot be steered! Under no circumstances may you drive the truck crane when the red lamp (1) is lit.

  • Page 195: Monitoring Elements

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.11 Monitoring elements Instrument panel Tachometer 1 Green: Economic consumption 2 Yellow: Engine brake active 3 Red: Engine speed too high – danger; à...

  • Page 196: Set Idling Speed

    Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.12 Set idling speed After the engine is started, the idling speed is regulated automatically. If necessary, you can adjust the idling speed manually. You can only set the idling speed when the truck crane is stationary.

  • Page 197: Switching Off The Engine

    Starting the engine for driving / switching it off 4.2 Switching off the engine Switching off the engine 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units Risk of accidents because the truck crane cannot be steered! Switch the engine off only once the truck crane has come to a standstill. If you remove the ignition key, the steering will lock and you will lose control of the moving truck crane.

  • Page 198: With Emergency Stop Switches

    Starting the engine for driving / switching it off 4.2 Switching off the engine 4.2.2 With emergency stop switches Emergency stop switch Four emergency stop switches are provided for emergencies: 1 On the carrier 2 On the hand-held control 3 In the crane cab •...

  • Page 199: Air Intake Inhibitor

    Starting the engine for driving / switching it off 4.3 Air intake inhibitor Air intake inhibitor If the air intake inhibitor is triggered, a flap in the air intake line will close and the engine will stop running. The air intake inhibitor is triggered, –...
  • Page 200 Starting the engine for driving / switching it off 4.3 Air intake inhibitor Blank page 4 - 24 3 302 633 en Operating Instructions GMK5250L...

  • Page 201: Driving

    Driving 5.1 Before driving Driving Before driving 5.1.1 CHECKLIST: Checks before on-road driving This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there! 1. If the boom is on the boom rest –...
  • Page 202 Driving 5.1 Before driving 4. On the outrigger – All outrigger beams must be fully retracted and secured to prevent à extension; p. 11 - 42. à – The outrigger pads must be in the driving position; p. 11 - 51. à...
  • Page 203 Driving 5.1 Before driving 10. Fold in all ladders and retract extend all stair treads; à Ladders , p. 4 - 5, à Step at the crane cab , p. 11 - 141. 11. Check the tyres: à – Tyre pressure when tyres are cold in on-road mode; p.
  • Page 204 Driving 5.1 Before driving 15. The detachable equipment parts must be stripped down so that they fulfil the regulations of the country in which you are working as regards permissible weights and axle loads, lengths, widths, height, etc. For a driving mode with a maximum axle load of 12 t (26,500 lbs); à...
  • Page 205 Driving 5.1 Before driving à 21. Adjust the steering column; p. 5 - 14. à 22. Adjust the mirrors; p. 5 - 7. à 23. Set the tachograph, insert the diagram sheet; p. 5 - 17. à Inspections after starting the 24.
  • Page 206 Driving 5.1 Before driving 26. Check the consumable reserve; à Standard tank , p. 4 - 7, – à AdBlue , p. 4 - 9. – à 27. Check the compressed air and brake systems; p. 5 - 10. 28. Check that all switching states for on-road driving are set, and that the corresponding symbols are shown: à...

  • Page 207: Check The Condition Of The Truck Crane

    Driving 5.1 Before driving 5.1.2 Check the condition of the truck crane • Electrical system Check the following functions and arrange for faulty parts to be repaired: – Parking light/headlight, rotating beacons, fog tail light, side marker lights, – Hazard warning system, –...
  • Page 208 Driving 5.1 Before driving Electrical adjustment • Turn the button to position A Neutral position B Mirror on the driver's side or C Mirror on the passenger side. • Press the button (5) – the mirror moves.: 1 Up 2 Right 3 Down 4 Left Mirror heating...
  • Page 209 Driving 5.1 Before driving Warning plates for Depending on the vehicle width, fold-up warning plates are fitted below the vehicle width driver's cab. The warning plates (1) must be folded down to indicate the vehicle width during on-road driving. For off-road driving, the warning plates can be folded up and fastened with the locking bar (2).
  • Page 210 Driving 5.1 Before driving Supply pressure The brake system and some consumers (e.g. differential locks, driver's seat, etc.) require sufficient supply pressure in order function properly. • Check that the supply pressure is approx. 8 bar (116 psi). If the supply pressure is too low, such as after repairs, you can build it up as follows.
  • Page 211 Driving 5.1 Before driving Parking brake Check the function of the parking brake. • Activate the service brake. Risk of accidents due to the truck crane moving unintentionally! Always apply the service brake before releasing the parking brake. This prevents the truck crane from rolling in an uncontrolled manner when the parking brake is released.

  • Page 212: Adjusting The Seats And Steering Column

    Driving 5.1 Before driving 5.1.3 Adjusting the seats and steering column Driver's seat The seat height and lumbar support are adjusted pneumatically. You can only make these adjustments when: – the switch (1) on the driver's seat is switched off (not pressed in), –...
  • Page 213 Driving 5.1 Before driving Settings for body shape 1 Lumbar area support 2 Seat cushion – longitudinal adjustment 3 Seat cushion – angle Passenger's seat The passenger's seat is adjusted mechanically. 1 Back rest – angle 2 Seat longitudinal adjustment 3 Seat cushion –...
  • Page 214 Driving 5.1 Before driving Steering column The steering column is unlocked pneumatically. adjustment Risk of accidents by unlocked steering column! Always stop the truck crane before you unlock the steering column. Once the steering column is unlocked you can no longer steer safely. The steering column is only unlocked when sufficient supply pressure is à...

  • Page 215: Switching The Suspension On/Off

    Driving 5.1 Before driving 5.1.4 Switching the suspension on/off The suspension is switched off whenever the ignition is switched off. The suspension must be switched on for on-road driving. The current switching state of the suspension is shown on the display (1) in all menus and also in the main menu (2).
  • Page 216 Driving 5.1 Before driving Switching the The suspension cylinders are enabled when the suspension is switched on. suspension on This state must be established for on-road driving. Danger of overturning when switching on the suspension! Do not switch the suspension on unless the truck crane has been rigged for on-road driving and the main boom has been set down.

  • Page 217: Setting The Tachograph

    Driving 5.1 Before driving 5.1.5 Setting the tachograph Diagram sheets (24-hour discs) can be inserted into the tachograph for two drivers simultaneously. As a crane operator, you are obligated to set each activity on the tachograph. This section only describes the basic operation of the tachograph (inserting diagram sheets, setting time groups, operating errors).
  • Page 218 Driving 5.1 Before driving Setting the To set the tachograph, you must first open the drawer and check the time tachograph setting. You can then insert the diagram sheets and set the time groups. Opening the drawer • Press the button (6) once. First the symbol (5) and the running bar (4) appear, then the drawer (3) opens.
  • Page 219 Driving 5.1 Before driving Inserting diagram sheets Only insert diagram sheets that are properly marked. The diagram sheets are always inserted with the front facing upwards. Risk of malfunctions in the electronics! If a diagram sheet has been damaged by being marked several times, this might cause malfunctions in the electronics.
  • Page 220 Driving 5.1 Before driving Display If there is no malfunction, the Tachograph display now shows the basic display: – Date (4) and time (5) – Driver 1 time group (1.1) – Driver 1 diagram sheet inserted (1.2) – Total kilometres of the truck crane (3) –...
  • Page 221 Driving 5.1 Before driving The different time groups are shown with the following symbols: Driving times: As soon as the vehicle starts to move, the tachograph auto- matically switches to the symbol for driver 1 driving time. If two diagram sheets are inserted, the tachograph automatically switches to stand-by time for 2-driver operation.

  • Page 222: Setting The Time

    Driving 5.1 Before driving 5.1.6 Setting the time • Open the Set display brightness and date/time menu (1). • Select and confirm the symbol (1). Setting the time • Select and confirm the symbol (2). • Select the current time – as a deviation from the UTC time.

  • Page 223: Displaying And Resetting Operating Hours

    Driving 5.1 Before driving 5.1.7 Displaying and resetting operating hours You can view the total operating hours for all power units in the Operating hours menu. You can also delete the recorded operating hours. The total operating hours cannot be deleted. •...
  • Page 224 Driving 5.1 Before driving Blank page 5 - 24 3 302 633 en Operating Instructions GMK5250L...

  • Page 225: Operating The Transmission

    Driving 5.2 Operating the transmission Operating the transmission The transmission automatically controls all gear changes. Despite this, gears can be changed manually at any time. 5.2.1 Switching on When the ignition is switched off, the transmission must always be in the neutral position.

  • Page 226: Switching The Transmission To The Neutral Position

    Driving 5.2 Operating the transmission 5.2.2 Switching the transmission to the neutral position You can switch the transmission to neutral position at any time. Risk of accidents when switching while driving! If you switch the transmission to neutral position while driving, the drive line will be interrupted.

  • Page 227: Selecting The Direction Of Travel And Starting Gear

    Driving 5.2 Operating the transmission 5.2.3 Selecting the direction of travel and starting gear à Selecting the Before driving at temperatures below -20 °C (-4 °F); p. 5 - 34. driving direction The following requirements must be met before selecting the driving direction: –...
  • Page 228 Driving 5.2 Operating the transmission For reverse travel The reverse camera is switched on. The display (1) shows the area behind the truck crane. When you exit the transmission mode R, the camera is switched off and the display (1) shows the CCS menu. Selecting the You can also change the gear that is automatically selected on starting.

  • Page 229: Changing The Operating Mode

    Driving 5.2 Operating the transmission 5.2.4 Changing the operating mode The display shows which operating mode is switched on. – Symbol (1) – Automatic operating mode on. – Symbol (2) – Manual operating mode on. It is possible to switch between the operating modes whilst the vehicle is stationary or whilst on the move.

  • Page 230: Starting

    Driving 5.2 Operating the transmission 5.2.5 Starting Risk posed by unexpected rolling! Also apply the parking brake before starting on sloping ground. The gear will be engaged only once you depress the accelerator. This can lead to the truck crane starting to move (perhaps backwards) whilst you are moving your foot from the brake pedal to the accelerator.

  • Page 231: Driving And Changing Gears

    Driving 5.2 Operating the transmission 5.2.6 Driving and changing gears • When driving, always leave the switch in the position for the current driving direction, e.g. in position D for forward travel. Risk of accidents due to changing transmission direction whilst driving! If whilst driving in one direction you select a gear for the opposite direction, the transmission shifts into the neutral position.
  • Page 232 Driving 5.2 Operating the transmission In manual In this operating mode, the transmission only shifts when you actuate the operating mode gearshift lever. Manual upshifting To upshift, you must pull the gearshift lever upwards briefly: – Upshifting one gear: Push up once –...

  • Page 233: Changing The Driving Direction

    Driving 5.2 Operating the transmission 5.2.7 Changing the driving direction • Stop the truck crane. • Shift to the position for the opposite direction. At a standstill, you can shift two levels in succession immediately. You do not need to wait for the intermediate position N to appear. The newly engaged gear will be shown in the display.

  • Page 234: On The Roller Type Dynamometer

    Driving 5.2 Operating the transmission 5.2.9 On the roller type dynamometer Danger of unexpectedly moving off rollers! Always shift to the neutral position on the roller type dynamometer. In position D or R, a suitable gear is engaged for the speed. The engine braking power is applied against the rollers and the truck crane can drive out of them.

  • Page 235: Driving And Parking Off The Truck Crane

    • Stop the vehicle as soon as possible. Briefly switch the ignition off then on again. If the lamp is still lit, contact Manitowoc Crane Care Operating Instructions GMK5250L 3 302 633 en 5 - 35...
  • Page 236 If oil has escaped • Warn any vehicles on the road behind you. • Do not continue driving. Contact Manitowoc Crane Care If no oil has escaped • Start the engine. – If all 3 lamps (1) light up: •...
  • Page 237 Driving 5.3 Driving and parking off the truck crane Lamps for the ABS system • Check the lamps (1). At speeds of above 6 km/h (4 mph), the lamps (1) must go out. Then the Anti Blocking System (ABS) is operational and the wheels are prevented from being blocked when you brake.
  • Page 238 Driving 5.3 Driving and parking off the truck crane – The brightness is reduced automatically if the temperature at the display is too high. Do not cover the sensors (1) and keep them clean to avoid contamination that can affect the brightness adjustment. •...

  • Page 239: Cruise Control

    Driving 5.3 Driving and parking off the truck crane 5.3.2 Cruise control Cruise control enables you to drive at a constant speed without pressing the accelerator. Risk of accidents due to carelessness! Be ready to brake at all times when cruise control is switched on! Switch cruise control on only if the traffic situation permits a constant speed.

  • Page 240: Temposet

    Driving 5.3 Driving and parking off the truck crane 5.3.3 Temposet You can use Temposet to limit the maximum speed. Switching on You can switch on Temposet only at speeds greater than 15 km/h (9 mph). • Press the button (1) once. Temposet is now switched on.

  • Page 241: Driving Downhill

    Driving 5.3 Driving and parking off the truck crane 5.3.4 Driving downhill Risk of accidents when driving in neutral position! Never switch into neutral position whilst driving. In neutral position, the truck crane may accelerate and the engine retarder is ineffective. Starting The engine must be running.
  • Page 242 Driving 5.3 Driving and parking off the truck crane Checks when While driving, the engine speed may not exceed 2,300 rpm. The engine driving downhill speed is not limited automatically. Risk of damage due to excessive engine speed! If the maximum permissible engine speed is reached, shift up to a higher gear or slow the truck crane down.
  • Page 243 Driving 5.3 Driving and parking off the truck crane Additional brakes Engine retarder The truck crane has an engine flap brake which it uses as an engine retarder. The engine retarder only becomes effective at an engine speed of 950 rpm and can be used up to a maximum speed of 2,300 rpm.

  • Page 244: Driving Uphill

    Driving 5.3 Driving and parking off the truck crane 5.3.5 Driving uphill Starting The engine must be running. Danger of the truck crane starting to roll away unexpectedly! When starting to move forwards, always keep the truck crane stationary with the parking brake until the transmission is engaged. If the truck crane starts to roll away before this (when changing from brake pedal to acceler- ator), no gear will be engaged, and you can stop the truck crane only by braking.

  • Page 245: Override Torque Reduction

    Driving 5.3 Driving and parking off the truck crane 5.3.6 Override torque reduction When the Adblue (DEF) supply is empty, the torque reduction is activated via the engine control system. You can override torque reduction up to 3 times. – If the level in the AdBlue tank falls to the reserve level, then the symbol (1) is displayed.

  • Page 246: Switching The Truck Crane Off

    Driving 5.3 Driving and parking off the truck crane 5.3.7 Switching the truck crane off To switch the truck crane off, you must: 1. Stop the truck crane 2. Apply the parking brake à 3. Switch to neutral position; p. 5 - 26 à...
  • Page 247 Driving 5.3 Driving and parking off the truck crane Using additional equipment, other chocks can be transported on the rear of the truck crane. • When stationary Switch off all current consumers, e.g. auxiliary heaters. for more than 8 • Switch the engine off.

  • Page 248: Folding Berth

    Driving 5.3 Driving and parking off the truck crane 5.3.8 Folding berth The berth must always be folded up for driving. Risk of accidents due to the berth folding down! Check that the locking bar has engaged and put up the back rest of the seats before driving.

  • Page 249: Off-Road Driving

    Driving 5.4 Off-road driving Off-road driving This section describes adjustments, connections and procedures for adapting the vehicle handling to off-road conditions. Adjustments to If you drive continuously for short periods of time with different loads or on the transmission a slippery surface, the transmission may switch gears too late or too early. In this event you can make the following adjustments: à...

  • Page 250: Longitudinal And Transverse Differential Locks

    Driving 5.4 Off-road driving 5.4.1 Longitudinal and transverse differential locks – The longitudinal differential locks prevent individual axle lines from spin- ning when driving on a slippery surface. With the 10 x 8 x 10 drive, the 3rd axle line is switched on and off together with the longitudinal differ- ential locks.
  • Page 251 Driving 5.4 Off-road driving Switching off • Select and confirm the symbol (1) for the – Longitudinal differential locks (A) or – Transverse differential locks (B). Display: – First symbol (2) – yellow, then symbol (3) – green, differential locks off. If symbol (3) is not green then drive back and forth slowly.

  • Page 252: Operating The Level Adjustment System

    – Set the on-road driving level, – Pre-select the suspension struts and change the vehicle level. If the error symbol (3) is shown during level adjustment, contact Manitowoc Crane Care 5 - 52 3 302 633 en Operating Instructions GMK5250L...
  • Page 253 Driving 5.4 Off-road driving Setting the For on-road driving, you must always set the on-road level in order to on-road level adhere to the specified overall height. • Park the truck crane on a level surface. • Straighten the steering. •...
  • Page 254 Driving 5.4 Off-road driving Changing the You can extend or retract the pre-selected suspension struts to change the vehicle level vehicle level. Risk of accidents by exceeding total permissible height! Always bring the truck crane to on-road level before driving on roads after changing the level.
  • Page 255 Driving 5.4 Off-road driving (A) – When the truck crane is level the marking (1) is in the middle. (B) – In this example, the carrier would be standing higher to the rear on the right hand side. You can exit the Suspension/Level adjustment system menu at any time. Exiting the menu •...

  • Page 256: Freeing An Immobilized Truck Crane

    Driving 5.4 Off-road driving 5.4.3 Freeing an immobilized truck crane Rocking the truck If the truck crane is stuck in terrain, you can try to free it by driving back and crane free forth (rocking it free): If you are trying to rock the crane free, you should switch on the transverse differential locks and the longitudinal differential lock.
  • Page 257 Driving 5.4 Off-road driving • Towing free to Fasten a steel rope to the front towbar coupling. the front Risk of damage to the chassis! Only tow the truck crane free while observing the procedure given for the pulling direction. Pulling out the truck crane jerkily or at an angle may damage the chassis.
  • Page 258 Driving 5.4 Off-road driving Blank page 5 - 58 3 302 633 en Operating Instructions GMK5250L...

  • Page 259: Separate Steering

    Driving 5.5 Separate steering Separate steering There are two steering modes with separate steering. – Driving around corners: When the separate steering is switched on, the steering angle is larger than for normal steering mode – the turning circle is smaller. –...
  • Page 260 – The symbols (5) are red – steering unlocked. When separate steering is switched on, the speed is limited to approx. 20 km/h (12 mph). If the error symbol is displayed, contact Manitowoc Crane Care • Manual Steer the 1st to 3rd axle lines with the steering wheel.
  • Page 261 Driving 5.5 Separate steering (A) – For driving around corners • Steer the 5th axle line opposite to the 1st to 3rd axle lines. The 4th axle line is steered to suit the turning radius. (B) – For crab travel mode •...
  • Page 262 Steer using the button (2) or the steering wheel (1) until the symbols (5) become green. à If the error symbol is displayed, contact p. 7 - 22. Manitowoc Crane Care 5 - 62 3 302 633 en Operating Instructions GMK5250L...

  • Page 263: Heating And Air-Conditioning System

    Driving 5.6 Heating and air-conditioning system Heating and air-conditioning system 5.6.1 Standard heating system • Switching on Start the engine. Heating is only available when the engine is running. Heating You must set the blower and the temperature. Setting the blower/fresh air/recirculated air You can regulate the air volume with the switch (1) for: A Recirculated air –...
  • Page 264 Driving 5.6 Heating and air-conditioning system Air distribution You can direct the air to flow out of various air vents. • Turn the switch (5) to the position for the required air vents. A Air vents (1), (2) – front windscreen, side B Air vents (1) to (4) C Air vents (2), (3), (4) –...
  • Page 265 Driving 5.6 Heating and air-conditioning system Examples This section only contains examples of the settings. Always adjust the setting to the current conditions (warm, cold, damp). (A) – Ventilate – Turn the switches to the positions shown. – If necessary, open the air vents for the side and centre.

  • Page 266: Air-Conditioning System

    Driving 5.6 Heating and air-conditioning system 5.6.2 Air-conditioning system You can cool the driver's cab and dry the air using the air-conditioning system. Information Do not cool the air too much. The difference between the outside temperature and the inside temperature should be at the most 10 °C to 14 °C (18 °F to 25 °F).
  • Page 267 Driving 5.6 Heating and air-conditioning system Cooling The illustration shows only a sample setting. Always adjust the setting to the current conditions. • Switch the air-conditioning system on – the lamp (4) lights up. • Turn the switch (3) as far as it will go, to Cold . •...

  • Page 268: Auxiliary Water Heater

    Driving 5.6 Heating and air-conditioning system 5.6.3 Auxiliary water heater The batteries will be drained if you operate the auxiliary heating system with the engine switched off. You must recharge the batteries at shorter intervals if you use the auxiliary heater frequently! You can use the auxiliary water heater to: –...
  • Page 269 Driving 5.6 Heating and air-conditioning system Preheating the Adjust the heating system as follows if the driver's cab is to be preheated in driver's cab addition to the engine: • Switch (2) to the warm position. • Switch (1) on the recirculated air symbol, level 1.
  • Page 270 Driving 5.6 Heating and air-conditioning system • Switching on the Check whether the auxiliary heater is allowed to be operated at the cur- auxiliary heater rent site of the truck crane before switching it on. Find out whether there are any possible sources of danger that could result in an explosion. Risk of explosion when operating the auxiliary heater! The auxiliary heater is not allowed to be operated: –...
  • Page 271 Driving 5.6 Heating and air-conditioning system Switching off the This section only describes how to switch off the heater manually. The auxiliary heater auxiliary heater is switched off again after a certain heating period if it was à Setting the switched on automatically.
  • Page 272 Driving 5.6 Heating and air-conditioning system Saving automatic Heating is started automatically on schedule only if the time and the day of à heating start the week have been correctly set; p. 5 - 71. You can set three different automatic heating starts – up to seven days in advance.
  • Page 273 Driving 5.6 Heating and air-conditioning system Setting the After an automatic start, the auxiliary heater switches itself off as soon as heating period the set heating period has elapsed. The heating period applies to all saved heating starts. • Switch off the auxiliary heater using the button (1). •...
  • Page 274 Driving 5.6 Heating and air-conditioning system Setting the If the ignition is turned off while the auxiliary heater is running, the auxiliary remaining time heater continues to run for the remaining time. • Switch on the auxiliary heater using the button (1). •...

  • Page 275: Auxiliary Air Heater

    Driving 5.6 Heating and air-conditioning system 5.6.4 Auxiliary air heater You can use the auxiliary air heating to preheat the driver's cab or provide additional heating. The batteries will be drained if you operate the auxiliary heater with the engine switched off. You must recharge the batteries at shorter intervals if you use the auxiliary heater frequently! Switching on To switch the auxiliary heater on and off, you can:...
  • Page 276 Driving 5.6 Heating and air-conditioning system Temperature You can preselect a temperature for the driver's cab. The preselected temperature is automatically set and maintained. Increasing the temperature: • Turn the switch (1) clockwise. Reducing the temperature: • Turn the switch (1) anti-clockwise. The higher the selected temperature is, the faster the fan of the auxiliary heater runs.
  • Page 277 Driving 5.7 Towing a trailer Towing a trailer When towing a trailer, a towbar coupling is fitted to the back of the carrier. Please observe the permissible trailer load of your truck crane. Risk of accidents by trailer moving unintentionally! Before coupling or uncoupling the trailer, it must be secured with the trailer parking brake as well as with chocks to prevent it from rolling away.
  • Page 278 Driving 5.7 Towing a trailer Coupling the trailer Risk of injury when the automatic closing device is triggered! Do not put your hand into the coupling jaw when the towbar coupling is open. This may activate the automatic closing device, causing the cotter pin to move down with great force, seriously injuring your hand.
  • Page 279 Driving 5.7 Towing a trailer Risk of accidents if the trailer is coupled improperly! If the pin is protruding from the guide bushing, the trailer is not coupled properly and could become disengaged from the towbar coupling while driving. Connecting the supply lines •...
  • Page 280 Driving 5.7 Towing a trailer Removing supply lines Risk of accidents due to trailer moving unintentionally! Always first remove the hose from the supply line so that the trailer is braked. This prevents the trailer from moving when you remove the brake hose.
  • Page 281 Driving 5.7 Towing a trailer Risk of injury when manually closing the towbar coupling! When closing, the lever moves down with great force in the direction of the coupling jaw. Start the closing process only by moving the lever briefly in the direction of the coupling jaw with the ball of your hand.
  • Page 282 Driving 5.7 Towing a trailer Checking the When a trailer is coupled and connected, you can check whether the braking braking force force of the truck crane alone is sufficient for braking the truck crane and the trailer on uphill or downhill roads (e.g. when a brake hose has burst). To check this, you can release the parking brake of the trailer on its own.

  • Page 283: Driving Modes And Rigging For On-Road Driving

    12 t (26,500 lbs). notes that Manitowoc Crane Group Germany GmbH driving with an axle load exceeding 12 t (26,500 lbs) the brake system can overheat and the braking deceleration required by the EU partial type- approval cannot be ensured.

  • Page 284: How To Use The Tables

    Driving modes and rigging for on-road driving 6.1 Driving modes 6.1.1 How to use the tables The tables consist of two parts: – The driving mode of your truck crane is specified in the top part, next to Equipment. Find out which driving mode applies to your truck crane. Each truck crane has one driving mode only.

  • Page 285: Tables For A Maximum Axle Load Of 12 T (26,500 Lbs)

    This section only shows some standard driving modes. For further information on additional or individual driving modes, please contact Manitowoc Crane Care If you remove indicated parts from the truck crane in driving mode, then the total weight decreases but can be distributed in such a way that the front or rear axle loads are over 12 t (26,500 lbs).
  • Page 286 Driving modes and rigging for on-road driving 6.1 Driving modes For tyres Driving mode 445/95 R25 525/80 R 25 ✔ ✔ ✔ ✔ ✔ ✔ 445/95 R 25 tyres 525/80 R 25 tyres ✔ ✔ ✔ ✔ ✔ ✔ Steel rims ✔...

  • Page 287: Maximum Permitted Speeds With An Axle Load Of Over 12 T (26,500 Lbs)

    Driving modes and rigging for on-road driving 6.1 Driving modes 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs) Should your national regulations allow driving with axle loads over 12 t (26,500 lbs), you may under no circumstances exceed the maximum permitted speed given here.
  • Page 288 Driving modes and rigging for on-road driving 6.1 Driving modes Blank page 6 - 6 3 302 633 en Operating Instructions GMK5250L...

  • Page 289: Weighing The Truck Crane

    Driving modes and rigging for on-road driving 6.2 Weighing the truck crane Weighing the truck crane Weighing error The most precise method for determining the total weight of the GMK5250L is to use calibrated scales of appropriate capacity and a weighbridge on which all the wheels of the truck crane can stand at the same time.
  • Page 290 Driving modes and rigging for on-road driving 6.2 Weighing the truck crane – Determining the axle loads All the axle lines belonging to an axle group must always be weighed. In addition, all the wheels must be on the same level. If for instance only the axle group A1 is to be weighed, then the axle groups A2 must be equalised on a support plate U which has...
  • Page 291 Driving modes and rigging for on-road driving 6.2 Weighing the truck crane Weighing procedure Perform the weighing procedure only with the crane truck standing on solid and horizontal ground. All scales must be at the same height. • Position the scales W1 to W4 (or the necessary support plate) directly in front of the truck crane, so that the distances between the scales are exactly the same as the distances between the axle groups 1 and 2.
  • Page 292 Driving modes and rigging for on-road driving 6.2 Weighing the truck crane Evaluation In the example shown you receive four weighing results. Assume you had made a note of the values listed here. Passenger side: W1 = 10 t, W3 = 12 t Driver's side: W2 = 10 t, W4 = 12 t These values allow you to determine the total weight of the truck crane and...

  • Page 293: Rigging Work For Driving With A Dolly

    Driving modes and rigging for on-road driving 6.3 Rigging work for driving with a dolly Rigging work for driving with a dolly To reduce the axle loads to the specifications applicable in the country in which you are working, you can set the main boom onto a dolly when driving.

  • Page 294: Switching On The Slewing Gear Freewheel

    Driving modes and rigging for on-road driving 6.3 Rigging work for driving with a dolly 6.3.1 Switching on the slewing gear freewheel When the main boom is set down on a dolly, the superstructure must be able to slew when driving around corners. You must switch on the slewing gear freewheel for this purpose.

  • Page 295: Switching On The Boom Floating Position

    Driving modes and rigging for on-road driving 6.3 Rigging work for driving with a dolly 6.3.2 Switching on the boom floating position If the main boom has been placed on a dolly, the boom floating position must be switched on so that the main boom can move up and down. Risk of accidents from the boom floating position being switched off Always switch on the boom floating position when the main boom is on a dolly.

  • Page 296: Switching On Boom Pre-Tensioning

    Driving modes and rigging for on-road driving 6.3 Rigging work for driving with a dolly 6.3.3 Switching on boom pre-tensioning If the main boom has been set down on a dolly, you can change the axle loads on the rear axle lines by switching on the boom pre-tensioning. •...

  • Page 297: Rigging The Main Boom

    Without this factory-installed pulling device, the main boom may only be removed by Manitowoc Crane Care Additional equip- In addition to the pulling devices, you also need the following accessories: ment required –...

  • Page 298: Checklist: Removing The Main Boom

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.1 CHECKLIST: Removing the main boom This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions specified there! Prerequisites –...
  • Page 299 Driving modes and rigging for on-road driving 6.4 Rigging the main boom 3. On the derricking cylinder head axle: – Take the load off of the head pin – Release the head pin – Pull the head pins out; à p.

  • Page 300: Checklist: Installing The Main Boom

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.2 CHECKLIST: installing the main boom This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions specified there! Prerequisites The truck crane is supported by an outrigger span of at least 8.950 x 2.710 m (29.4 x 8.8 ft).
  • Page 301 Driving modes and rigging for on-road driving 6.4 Rigging the main boom 4. On the boom pivot pin: – Open the hydraulic circuit, – Extend the pivot pin, – Securing the pulling device, – Close the hydraulic circuit, à p. 6 - 26. 5.

  • Page 302: Slinging The Main Boom

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.3 Slinging the main boom Slings are fitted to the main boom when rigging and it is lifted with an à auxiliary crane. Note the equipment necessary for this; p.
  • Page 303 Driving modes and rigging for on-road driving 6.4 Rigging the main boom • Insert the bracket (3) into the slinging point (1). Pull the pin (2). • Insert the bracket into the slinging point (4). • Secure the bracket with the pin (2) and the retaining pin.
  • Page 304 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Blank page 6 - 22 3 302 633 en Operating Instructions GMK5250L...

  • Page 305: Retracting/Fitting The Derricking Cylinder Head Pin

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.4 Retracting/fitting the derricking cylinder head pin The derricking cylinder head axle is retracted and fitted with a pulling device. You must lower the main boom onto the main boom rest before pulling off the head pin.
  • Page 306 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Pulling the After you have pulled the head pin, you can no longer derrick the main derricking cylinder boom. head axle (A) – Releasing the head pin • Loosen the bolt (3) and remove the disc.
  • Page 307 Driving modes and rigging for on-road driving 6.4 Rigging the main boom • Fitting the Check to see if the tightening belt of the derricking cylinder is taken off. derricking cylinder head axle Aligning the derricking cylinder • (A) – Remove the bolt (1) and remove the disc.

  • Page 308: Retracting/Extending The Boom Pivot Pin

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.5 Retracting/extending the boom pivot pin The boom pivot pin is retracted and extended with a hydraulic pulling device. Before retracting Before retracting the boom pivot pin you must: –...
  • Page 309 Driving modes and rigging for on-road driving 6.4 Rigging the main boom After extending After extending the boom pivot pin you must: – close the hydraulic circuit, – secure the pulling device. Closing the hydraulic circuit • Close the valves (1) – position horizontal. Risk of accidents from falling main boom! Always secure the pulling device with the pins.
  • Page 310 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Retracting/ extending the pivot pin Risk of damage to the main boom! Before retracting, the main boom must be slung and all other sling gear must be tightened. Before extending, the bearing points on the turntable must be aligned with the boom pivot pin.

  • Page 311: Disconnecting/Connecting Hydraulics/Electrical

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.6 Disconnecting/connecting hydraulics/electrical Disconnecting The number of hoses/cables depends on how the truck crane is equipped. Risk of malfunction in the superstructure electronics! Always turn off the ignition in the crane cab before you establish or sepa- rate the electrical connection.
  • Page 312 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Connecting The number of hoses/cables depends on how the truck crane is equipped. Risk of malfunction in the superstructure electronics! Always turn off the ignition in the crane cab before you establish or sepa- rate the electrical connection.

  • Page 313: Lifting The Main Boom Off/On The Turntable

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.7 Lifting the main boom off/on the turntable à – The main boom is slung; p. 6 - 20. à – The hydraulic/electrical connections are disconnected; p. 6 - 29. à...

  • Page 314: Aligning The Connecting Points

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom Lifting on to the turntable • Lift the main boom backwards and down- wards on to the turntable. Make sure that: – The connection lines (3) do not hang loose, –...

  • Page 315: Transporting The Main Boom

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.9 Transporting the main boom Transport the main boom only on a separate vehicle which is of sufficient size and has sufficient lifting capacity. à Operating Instructions . Transport dimensions and weight;...

  • Page 316: Inspections After Main Boom Mounting

    Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.10 Inspections after main boom mounting • Switch on the ignition. • Check if the RCL (1) or CCS (2) control unit shows an error message. • If an error message is displayed, check that all electrical connections are established;...

  • Page 317: Installing/Removing The Outrigger Beams

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams Installing/removing the outrigger beams To rig the outrigger beams, the outriggers must be fitted with hydraulic connections (1) which can be separated. During rigging, each outrigger beam is removed and mounted as a com- plete “package”, consisting of inner and outer outrigger beams, cylinders and add-on parts.

  • Page 318: Checklist: Removing The Outrigger Beams

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.1 CHECKLIST: Removing the outrigger beams This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there! 1.
  • Page 319 Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams à 6. Release the connection to the support box; p. 6 - 49. 7. Sling the outrigger beam and pull it out of the outrigger box until it à...

  • Page 320: Checklist: Installing The Outrigger Beams

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.2 CHECKLIST: Installing the outrigger beams This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there! 1.
  • Page 321 Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams à 6. Screw in the spacers; p. 6 - 47. à 7. If necessary put outrigger pads into position; p. 6 - 43. 8. Mount all necessary outrigger beams in the same way in accordance with this checklist.

  • Page 322: Preparations - For Removal

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.3 Preparations – for removal Labelling the outrigger beams Each outrigger beam is designed for just one installation point. If, for exam- ple, you remove the outrigger beam on the rear left hand side, you must mount the same outrigger beam on the rear left hand side again.

  • Page 323: Preparations - For Installation/Removal Using The Truck Crane

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.5 Preparations – for installation/removal using the truck crane With an appropriately programmed RCL, you can carry out removal/instal- lation of the rear outrigger beams in the same way as described in the oper- ating instructions supplied and use the truck crane instead of an auxiliary crane to pull out/insert the outrigger beams.
  • Page 324 Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams Rigging the outrigger span • Observe all information on selection of the location and determining the à Selecting required load-bearing area before rigging the outrigger span; the suitable site , p. 11 - 9. •...

  • Page 325: Removing/Attaching Outrigger Pads

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.6 Removing/attaching outrigger pads You only need remove the outrigger pads if the outrigger beams are to be transported lying on their side. For transportation in a suitable holding frame, the outrigger beams can be set down on the outrigger pad.
  • Page 326 Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams Attaching the After mounting the outrigger beam, you must attach the outrigger pad. outrigger pads • (A) – Remove the pin (1). • Extend the outrigger cylinder far enough so that the bearing surface (3) is below the guide (2).

  • Page 327: Disconnecting/Establishing Hydraulic Connection

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.7 Disconnecting/establishing hydraulic connection There is a valve block on each outrigger beam. The position of the valve block may differ from the drawings, depending on the outrigger beam. Disconnecting a connection Always disconnect all connections (4).

  • Page 328: Disconnecting/Establishing The Electrical Connection

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.8 Disconnecting/establishing the electrical connection The electrical connection is only present on truck cranes equipped with an outrigger pressure display or outrigger span monitoring system. Risk of malfunctions in the electronic system! Always turn off the ignition before you disconnect or establish the electrical connection.

  • Page 329: Unscrewing/Screwing In The Spacers

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.9 Unscrewing/screwing in the spacers There are two spacers for each outrigger beam – In the outrigger box – In the outrigger beam on the opposite side. The illustrations show as an example the spacers for the outrigger beams on the front left hand side.
  • Page 330 Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams Screwing in Before you retract/extend an outrigger beam after mounting, you must screw in the spacers. At the outrigger box • Screw in the screws (1) as far as possible until the spacers (3) are touching the outrig- ger beam (4) at the top.

  • Page 331: Disconnecting/Establishing The Connections To The Outrigger Box

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.10 Disconnecting/establishing the connections to the outrigger The illustrations show as an example the connecting points for the outrig- ger beam on the rear right hand side. (A) – Disconnecting •...
  • Page 332 Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams • Using the auxiliary crane, sling the outrigger beam in the centre of gravity (2). • Remove the chain hoist and lifting gear. Fasten a guide rope (1). •...
  • Page 333 Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams • Inserting the Only insert the outrigger beam at the correct installation point. Note the outrigger beam information on the label. Risk of being crushed by the swinging outrigger beam! Do not guide the outrigger beam with your hands when inserting it.
  • Page 334 Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams • Lift the outrigger beam as far as possible into the outrigger box. Correct the height so that it does not remain hanging on the edges (1). • Remove the lifting gear from the centre of gravity.

  • Page 335: Transporting The Outrigger Beams

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.12 Transporting the outrigger beams • For transportation, be sure to use a separate vehicle with sufficient load à bearing capacity. Transport dimensions and weight; p. 1 - 10. •...

  • Page 336: Note On Error Messages With Removed Outrigger Beams

    Driving modes and rigging for on-road driving 6.5 Installing/removing the outrigger beams 6.5.13 Note on error messages with removed outrigger beams After removing the outrigger beams the error messages listed here occur. 5801.7.33.2 5809.7.32.96 5801.7.33.98 5803.7.32.2 5807.7.32.96 5803.7.32.98 The error messages indicate only that the electrical connection between the outrigger beams and the crane control is disconnected.

  • Page 337: Rigging The Auxiliary Hoist

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist Rigging the auxiliary hoist You need the following equipment: – suitable lifting gear and guide ropes with sufficient bearing capacity, – a separate vehicle, – if necessary, a rigging frame for rigging counterweight combinations up to max.
  • Page 338 Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 4. Slew the superstructure to the 0° to the rear position; à Slewing with the rigged counterweight , p. 11 - 93, à Current slewing angle display , p. 10 - 50. à...

  • Page 339: Checklist: Removing The Auxiliary Hoist

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 6.6.2 CHECKLIST: Removing the auxiliary hoist Prerequisites – The truck crane is supported with the required outrigger span as specified à in the lifting capacity table ; p. 11 - 28. –...
  • Page 340 Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 5. If necessary, disconnect the hand-held control and stow it away; à Connecting/disconnecting the hand-held control , p. 11 - 21. à 6. – Disconnect the hydraulic connections; p.

  • Page 341: Slinging The Auxiliary Hoist

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 6.6.3 Slinging the auxiliary hoist Risk of damage to the auxiliary hoist and truck crane Only sling the auxiliary hoist onto the slinging points provided. Always use lifting gear with a sufficient lifting capacity. •...

  • Page 342: Lowering/Raising The Rigging Frame

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 6.6.5 Lowering/raising the rigging frame Prerequisite – A minimum of the 7 t base plate lies on the counterweight platform, – A maximum counterweight combination of 21 t lies on the counterweight platform.

  • Page 343: Establishing/Disconnecting The Hydraulic Connection

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 6.6.7 Establishing/disconnecting the hydraulic connection Risk of damage to hydraulic lines! Lay the hydraulic hoses so that they will not be damaged during rigging and crane operation. Establishing a connection The assignment is given by the size and colour designations.

  • Page 344: Establishing/Disconnecting The Electrical Connection

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 6.6.8 Establishing/disconnecting the electrical connection Establishing a connection • Remove the plug (2) from the dummy socket (3) and plug it into the socket (1). • Close the dummy socket (3). Disconnecting a connection •...

  • Page 345: Creating The Connection To The Turntable

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 6.6.9 Creating the connection to the turntable Risk of being crushed when rigging the auxiliary hoist! Make sure that you or any helpers keep all parts of the body a sufficient distance away from the auxiliary hoist when rigging the auxiliary hoist.
  • Page 346 Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist Risk of accident when the safety valve is open! Always close the safety valve when the auxiliary hoist is locked to the turntable.! This prevents the auxiliary hoist from falling down due to unintentional actuation of the locking cylinders.
  • Page 347 Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist Disconnecting a connection Lowering the lifting frame • Press the buttons (3) and (4). • Press the buttons (2) until the locking points (1) are relieved. Retracting the locking cylinders •...

  • Page 348: Securing The Hoist Rope

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 6.6.10 Securing the hoist rope If you have wound up the hoist rope, you must secure it prior to removal. Risk of accident from damaged auxiliary hoist rope! Always secure the hoist rope prior to removal.

  • Page 349: Transporting The Auxiliary Hoist

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 6.6.11 Transporting the auxiliary hoist • For transportation, be sure to use a separate vehicle with sufficient load à bearing capacity. Transport dimensions and weight; p. 1 - 10. •...

  • Page 350: Check That The Auxiliary Hoist Is Functioning Properly

    Check the function of the slewing indicator when applying the hoist rope. • You must feel a pulse on the slewing indicator (1) when the auxiliary hoist is rotating. • If no pulse is present, contact Manitowoc Crane Care 6 - 68 3 302 633 en Operating Instructions GMK5250L...

  • Page 351: Rigging Aid For The Hoist Rope

    Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist 6.6.13 Rigging aid for the hoist rope Depending on the version, a rigging aid for the hoist rope is provided with the auxiliary hoist. Scope of delivery 1 Connector, two parts 2 Rope Risk of damage to the hoist rope! Always rig the hoist rope with the rigging aid.
  • Page 352 Driving modes and rigging for on-road driving 6.6 Rigging the auxiliary hoist Rigging the hoist rope The rigging aid is connected to the hoist rope. – When rigging • Guide the rope (1) over the main boom and over the upper head sheave. •...

  • Page 353: Malfunctions In Driving Mode

    Malfunctions in driving mode 7.1 Emergency stop switch Malfunctions in driving mode Emergency stop switch Four emergency stop switches are provided for emergencies: 1 On the carrier 2 On the hand-held control 3 In the crane cab • Press an emergency stop switch (1), (2) or (3).

  • Page 354: Procedure During Malfunctions

    When in a hazard area, carry out only the repair work required to leave the danger area. If you are unable to repair the damage yourself, notify Manitowoc Crane Care à Towing away the truck crane , p. 7 - 27.

  • Page 355: Procedure During Engine Malfunctions

    Do not by any means restart the engine. This will prevent serious damage to the engine. • If necessary, note the error messages and contact Manitowoc Crane Care a qualified specialist workshop. The coolant temperature is too high – the motor output is automatically reduced.

  • Page 356: Procedure During Transmission Malfunctions

    If the transmission malfunctions, the electronic system will try to establish a secure operating condition with the remaining functions. Even if the transmission still shifts, always notify Manitowoc Crane Care This avoid situations where another small error could lead to transmission failure.

  • Page 357: Warning And Error Messages

    Program version Always note down the number of the program version and the serial number after a malfunction occurs before notifying Manitowoc Crane Care The serial number (1) is shown in the Start menu. à The program version is displayed in the crane cab;...
  • Page 358 Malfunctions in driving mode 7.3 Warning and error messages Steering circuit 1 or 2 warning à Malfunctions Malfunction in steering circuit 1 or 2 – check for loss of oil; of the steering , p. 7 - 22. Steering circuit 3 warning (emergency steering pump) à...

  • Page 359: Warning And Malfunction Messages On The On-Board Computer Display

    Malfunctions in driving mode 7.3 Warning and error messages 7.3.2 Warning and malfunction messages on the on-board computer display Messages Messages are shown automatically. There are three types of message. – Warning message Display (1) red, additional text and symbols. •...
  • Page 360 • Add oil if necessary. If the error message persists, contact Manitowoc Crane Care Risk of damage to the engine if the oil pressure drops! Switch off the engine as soon as possible and look for the cause if the lamp...
  • Page 361 The gear shifting has a malfunction – driving can continue with restrictions. • If necessary, note the error messages and contact Manitowoc Crane Care a qualified specialist workshop. The clutch has a malfunction – driving can continue with restrictions. •...
  • Page 362 Malfunctions in driving mode 7.3 Warning and error messages The maximum permissible operating temperature of the clutch has been reached. • Shift to a lower gear for manoeuvring or starting. • stop the manoeuvring or starting procedure. The oil temperature of the fluid coupling is too high. •...

  • Page 363: Warning Messages On The Ccs Display

    Malfunctions in driving mode 7.3 Warning and error messages 7.3.3 Warning messages on the CCS display A warning message indicates that certain values do not correspond to a target value When CCS detects a fault then the display area (1) shows an error or warning symbol. Meaning of the symbols The colour of the symbols indicates whether a warning or malfunction message is active in the corresponding area.
  • Page 364 Malfunctions in driving mode 7.3 Warning and error messages AdBlue (DEF) – Filling level à AdBlue (DEF) – top up the reservoir; p. 4 - 9. Replace the hydraulic oil filter • Replace the corresponding hydraulic oil filter as quickly as possible; à...
  • Page 365 Malfunctions in driving mode 7.3 Warning and error messages Coolant level too low Immediately top up the coolant so that the engine does not overheat; à Maintenance Manual . Coolant too hot The engine coolant is hotter than approx. 110 °C. à...
  • Page 366 7 - 15. CAN bus malfunction • Switch off the ignition and wait about 15 seconds, then switch it on again. If the malfunction is still present, contact Manitowoc Crane Care 7 - 14 3 302 633 en Operating Instructions GMK5250L...

  • Page 367: Engine/Transmission Error Messages

    – The symbols for the faulty components: 1 Engine 2 Transmission • Always note the error code before contact- Manitowoc Crane Care Exiting the menu You can exit the Engine errors menu at any time. • Press the button (1) once.
  • Page 368 Malfunctions in driving mode 7.3 Warning and error messages Blank page 7 - 16 3 302 633 en Operating Instructions GMK5250L...

  • Page 369: Troubleshooting

    Malfunctions in driving mode 7.4 Troubleshooting Troubleshooting This section does not include all malfunctions. – If a warning is shown in the display (1); à p. 7 - 11. – If the lamp on the instrument panel (2) lights à p.
  • Page 370 – the performance in order to drive on to the next will increase again place where it is possible to stop Other malfunctions: must be Manitowoc Crane Care notified 7 - 18 3 302 633 en Operating Instructions GMK5250L...

  • Page 371: Faults On The Adblue (Def) System

    4 - 9 – Flashes Adblue (DEF) tank empty – Adblue (DEF) tank sensor Have the exhaust system faulty checked by Manitowoc – Light up – Error in the Adblue (DEF) , an authorised Crane Care dosing unit GROVE retailer or an –...

  • Page 372: Malfunctions In The Transmission

    Malfunctions in driving mode 7.4 Troubleshooting 7.4.3 Malfunctions in the transmission Malfunction Cause Remedy à Transmission only shifts up Transmission oil too hot On the transmission , to second gear p. 7 - 28 Gear oil colder than approx. Wait until gear oil temper- -7 °C (20 °F) ature rises Transmission is not...

  • Page 373: Malfunctions Of The Service Brake

    Malfunctions in driving mode 7.4 Troubleshooting 7.4.4 Malfunctions of the service brake Malfunction Cause Remedy Lights up while The air pressure in one of the The vehicle can be driven driving or does not two circuits has fallen below slowly to the next repair shop go out after the 5.5 bar (80 psi) engine is started...

  • Page 374: Malfunctions Of The Steering

    7 - 38 Separate steering not CCS malfunction Note the error code à working and the CCS p. 7 - 11) and notify display shows an error Manitowoc Crane Care message 7 - 22 3 302 633 en Operating Instructions GMK5250L...

  • Page 375: Malfunctions Of The Differential Locks

    5 - 50 Error symbol is displayed CCS malfunction Note the error code à p. 7 - 11) and notify Manitowoc Crane Care 7.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler Malfunction Cause Remedy Hydraulic oil temperature...

  • Page 376: Malfunctions On The Suspension

    7 - 38 Error symbol is displayed CCS malfunction Note the error code à p. 7 - 11) and notify Manitowoc Crane Care 7.4.9 Malfunctions of the level adjustment system Malfunction Cause Remedy à Switching the suspension on ,...

  • Page 377: Emergency Operation And Breakdown Assistance

    Malfunctions in driving mode 7.5 Emergency operation and breakdown assistance Emergency operation and breakdown assistance 7.5.1 Externally starting the truck crane • Start the engine of the auxiliary vehicle. • (A) – Connect the cable (1) to the auxiliary vehicle's power supply (24 V). •...

  • Page 378: Battery Charger

    Malfunctions in driving mode 7.5 Emergency operation and breakdown assistance 7.5.2 Battery charger Prerequisites – The engine must not be running and must be secured against unau- thorised use, – An external 230 V mains power supply must be available at the location, –...

  • Page 379: Towing Away The Truck Crane

    If the wheels can no longer be steered into the forward position, notify prior to towing. Manitowoc Crane Care – If the engine, steering or service brake no longer function properly, the truck crane must be towed with a special breakdown truck.
  • Page 380 Malfunctions in driving mode 7.5 Emergency operation and breakdown assistance • Connect the filler connection (2) with the Supply coupling head of the towing vehicle. A supply pressure of at least 6 bar (87 psi) must be displayed and the lamps (1) must not light up in the driver's cab when towing.
  • Page 381 , p. 5 - 10. If the lamp (1) fails to go out, the parking brake has been damaged, contact Manitowoc Crane Care Risk of accidents due to faulty brakes! If the service brake system has been damaged, you may only tow the truck...

  • Page 382: Wheel Change

    Tow the truck crane at a maximum speed of 10 km/h (6 mph) and over a dis- tance of max. 1 km (0.62 mi). Additional measures must be taken for longer distances, contact Manitowoc Crane Care Tow starting It is not possible for the truck crane to start towing for transmission reasons.
  • Page 383 Malfunctions in driving mode 7.5 Emergency operation and breakdown assistance à • Removing a Switch off the suspension; p. 5 - 16. damaged wheel • Raise the truck crane with the outriggers until the wheel to be changed just barely leaves the ground. Risk of accidents due to a wheel falling over! When unscrewing the final lug nuts, the wheel can slip off the hub and fall toward you.
  • Page 384 Malfunctions in driving mode 7.5 Emergency operation and breakdown assistance Removing a wheel • Loosen the nuts (1). • Lift the spare wheel off the spare wheel holder. • Secure the spare wheel against falling over if you put it down temporarily. Mounting a wheel •...
  • Page 385 Malfunctions in driving mode 7.5 Emergency operation and breakdown assistance • Tighten the wheel nuts (1) and (2) finger- tight to secure the wheel. • Tighten the remaining wheel nuts finger- tight. • Always tighten the wheel nuts in the order (1) to (12).

  • Page 386: Inflating The Tyres Yourself

    Malfunctions in driving mode 7.5 Emergency operation and breakdown assistance 7.5.5 Inflating the tyres yourself In an emergency, if an appropriate filling hose is available you can inflate the tyres using the compressed air system of the truck crane. The tyres can be inflated up to a maximum pressure of about 8 bar (116 psi). This pressure might not correspond to the prescribed tyre pressure, à...
  • Page 387 Malfunctions in driving mode 7.5 Emergency operation and breakdown assistance Inflating the tyres The maximum operation pressure of the compressed air system of 8 bar (116 psi) can only be reached with the engine running. à • Start the engine; p.
  • Page 388 Malfunctions in driving mode 7.5 Emergency operation and breakdown assistance Blank page 7 - 36 3 302 633 en Operating Instructions GMK5250L...

  • Page 389: Fuses

    If a fuse with the same amperage fails again once the ignition is switched on, then notify Manitowoc Crane Care Risk of fire! Never repair a blown fuse with other electrically conductive materials. Operating Instructions GMK5250L...

  • Page 390: Fuses In The Driver's Cab

    Malfunctions in driving mode 7.6 Fuses 7.6.1 Fuses in the driver's cab • Remove the cover (1). 2 Fuse groups F1 to F4, F6 3 Other fuses 4 Reserve fuses The following sections show the designations of the individual fuses, including their amper- age and functions.
  • Page 391 Malfunctions in driving mode 7.6 Fuses Group F2 Designation Amperage (A) Function F2/1 UB1 IOL 32 F2/2 UB1 IOL 32 F2/3 UB2 IOL 32 F2/4 UB2 IOL 32 F2/5 UB1 IOL 33 F2/6 UB1 IOL 33 F2/7 UB2 IOL 33 F2/8 UB2 IOL 33 Group F3...
  • Page 392 Malfunctions in driving mode 7.6 Fuses Group F6 Designation Amperage (A) Function F6/1 Left low-beam headlight F6/2 Right low-beam headlight F6/3 XSM 08 F6/4 – Unassigned F6/5 – Unassigned F6/6 – Unassigned F6/7 – Unassigned F6/8 – Unassigned Other fuses Designation Amperage (A) Function...
  • Page 393 Malfunctions in driving mode 7.6 Fuses Designation Amperage (A) Function Driver's cab interface, left-hand side marker lights and parking light Transmission control right-hand side marker lights and parking light marker light and tail lamps, left-hand instrument lighting Right-hand marker light and tail lamps Seat heating, fan motor, left headlight, BirdView system 270°...

  • Page 394: Fuses In The Battery Box

    Malfunctions in driving mode 7.6 Fuses 7.6.2 Fuses in the battery box Fuses F7 to F15 are contained in the battery box. Danger from lead and lead compounds on batteries! Battery poles, battery terminals and parts of the battery itself contain lead and lead compounds.

  • Page 395: Operating Elements For Crane Operation

    Operating elements for crane operation 8.1 Overview of the operating elements Operating elements for crane operation All operating elements for driving are described in Chapter 3. Overview of the operating elements This section shows the position and designations of the operating elements for crane operation.

  • Page 396: Exterior Of The Truck Crane

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.1 Exterior of the truck crane 8 - 2 3 302 633 en Operating Instructions GMK5250L...
  • Page 397 Operating elements for crane operation 8.1 Overview of the operating elements à 1 – Camera on main boom p. 11 - 137 à – Camera on the hoists p. 11 - 139 à – Camera on the driver's cab p. 11 - 139 à...
  • Page 398 Operating elements for crane operation 8.1 Overview of the operating elements 8 - 4 3 302 633 en Operating Instructions GMK5250L...
  • Page 399 Operating elements for crane operation 8.1 Overview of the operating elements à 18 Switching on boom pre-tensioning p. 6 - 14 à Switching off boom pre-tensioning p. 11 - 19 19 Outrigger à – Control units p. 8 - 79 à...

  • Page 400: Crane Cab

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.2 Crane cab 8 - 6 3 302 633 en Operating Instructions GMK5250L...
  • Page 401 Operating elements for crane operation 8.1 Overview of the operating elements à 1 Side panel p. 8 - 8 2 Sun visor à 3 Degree of utilisation display p. 10 - 51 à 4 Door unlocking mechanism p. 8 - 148 à...
  • Page 402 Operating elements for crane operation 8.1 Overview of the operating elements Side panel 8 - 8 3 302 633 en Operating Instructions GMK5250L...
  • Page 403 Operating elements for crane operation 8.1 Overview of the operating elements à 1 – Start the engine p. 8 - 85 à – Set idling speed p. 8 - 85 2 RCL override – Version A à – RCL override p.
  • Page 404 Operating elements for crane operation 8.1 Overview of the operating elements Crane cab, rear 8 - 10 3 302 633 en Operating Instructions GMK5250L...
  • Page 405 Operating elements for crane operation 8.1 Overview of the operating elements à 1 Cab lighting p. 8 - 140 2 Sun roller blind 1), 3) 3 Radio-CD/USB 4 Loudspeakers 5 Socket (12 V) 6 Fan with switch à 7 Rear window p.

  • Page 406: Control Panels

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.3 Control panels Left à 1 Moving the outrigger p. 8 - 97 à 2 Slewing gear on/off p. 8 - 113 à 3 Lifting limit switch override p. 8 - 110 à...
  • Page 407 Operating elements for crane operation 8.1 Overview of the operating elements Right à 1 Jog dial (rotary push button) p. 8 - 89 à 2 Main hoist on/off p. 8 - 109 à 3 Derricking gear on/off p. 8 - 115 à...

  • Page 408: Control Lever Configuration

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.4 Control lever configuration The truck crane can be equipped with two different control lever configura- tions. The current configuration of the control levers is indicated by symbols on the control levers. In version 1, the left control lever is configured with the Telescope function.
  • Page 409 Operating elements for crane operation 8.1 Overview of the operating elements In version 2, the right control lever is assigned the Telescope function. Version 2 Left control lever Right control lever 1 Slew to the left Raise/retract 2 Slew to the right Lower/extend 3 Lower auxiliary hoist Lower the main hoist...

  • Page 410: Ccs Control Unit

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.5 CCS control unit 8 - 16 3 302 633 en Operating Instructions GMK5250L...
  • Page 411 Operating elements for crane operation 8.1 Overview of the operating elements à 1 CCS display p. 8 - 89 à Overview start menu p. 8 - 19 2 Jog dial à 3 Exiting the menu/input mode p. 8 - 92 4 no function à...

  • Page 412: Ccs - Menu-Dependent Displays

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.6 CCS – menu-dependent displays à 1 Slewing gear p. 8 - 113 à 2 Telescoping mechanism p. 8 - 117 à 3 Derricking gear p. 8 - 115 à...

  • Page 413: Ccs - Start Menu

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.7 CCS – Start menu The Start menu shows the key measured values. à 1 RCL display p. 8 - 20 à 2 Engine speed display p. 9 - 6 à...
  • Page 414 Operating elements for crane operation 8.1 Overview of the operating elements RCL display à 1 Slewing ranges/working radii display p. 8 - 21 à 2 Current working radius display p. 8 - 128 à 3 Current slewing angle display p. 8 - 128 à...
  • Page 415 Operating elements for crane operation 8.1 Overview of the operating elements Slewing ranges/ working radii display A For the Standard slewing range type B For the MAXbase slewing range type à Display of current slewing range divisions p. 8 - 127 à...

  • Page 416: Ccs - Overview Menu Groups

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.8 CCS – Overview menu groups 8 - 22 3 302 633 en Operating Instructions GMK5250L...
  • Page 417 Operating elements for crane operation 8.1 Overview of the operating elements à 1 Superstructure menu group p. 8 - 26 – Superstructure lock sub-menu – Counterweight menu à 2 Outrigger menu group p. 8 - 29 – Outrigger cylinders menu –...
  • Page 418 Operating elements for crane operation 8.1 Overview of the operating elements 8 - 24 3 302 633 en Operating Instructions GMK5250L...
  • Page 419 Operating elements for crane operation 8.1 Overview of the operating elements à 8 Settings menu group p. 8 - 60 – Crane cab menu – Set display brightness and date/time menu – Switch units menu – Set control lever characteristic curve menu –...

  • Page 420: Superstructure Menu Group

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.9 Superstructure menu group à 1 Superstructure lock sub-menu p. 8 - 27 à 2 Counterweight menu p. 8 - 28 8 - 26 3 302 633 en Operating Instructions GMK5250L...
  • Page 421 Operating elements for crane operation 8.1 Overview of the operating elements Superstructure lock sub-menu à 1 House lock locking status displays p. 8 - 125 à 2 Houselock on/off p. 8 - 125 à 3 Current slewing angle display p. 8 - 125 à...
  • Page 422 Operating elements for crane operation 8.1 Overview of the operating elements Counterweight menu à 1 Display of slewing direction for automatic mode p. 8 - 105 à 2 Current slewing angle display p. 8 - 108 à 3 Retracting the lifting cylinders p.

  • Page 423: Outrigger Menu Group

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.10 Outrigger menu group à 1 Outrigger cylinders menu p. 8 - 30 à Outrigger menu p. 8 - 32 Operating Instructions GMK5250L 3 302 633 en 8 - 29...
  • Page 424 Operating elements for crane operation 8.1 Overview of the operating elements Outrigger cylinders menu 8 - 30 3 302 633 en Operating Instructions GMK5250L...
  • Page 425 Operating elements for crane operation 8.1 Overview of the operating elements à 1 Slewing gear/movements locked display p. 8 - 96 à 2 Pre-select front left outrigger cylinder display p. 8 - 97 à 2.1 Pre-select front left outrigger cylinder p.
  • Page 426 Operating elements for crane operation 8.1 Overview of the operating elements Outrigger menu à 1 Slewing gear/movements locked display p. 8 - 96 à 2 Pre-select front left outrigger display p. 8 - 97 à 2.1 Pre-select front left outrigger p.

  • Page 427: Rcl/Telescoping Menu Group

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.11 RCL/Telescoping menu group à 1 Enter rigging mode/telescope status menu p. 8 - 34 à 2 Lifting capacity tables menu p. 8 - 40 à 3 Telescoping semi-automation menu p.
  • Page 428 Operating elements for crane operation 8.1 Overview of the operating elements – For the Standard slewing range type Enter rigging mode/telescope status menu A For boom system main boom B For boom system lattice extension Depending on the version, the top view (2) is shown rotated by 180°. The representation occurs in the same manner as in the RCL Monitoring à...
  • Page 429 Operating elements for crane operation 8.1 Overview of the operating elements à 1 Enter slewing range p. 8 - 130 à 2 Enter outrigger span p. 8 - 133 à Outrigger span monitoring display p. 8 - 134 à 3 Enter counterweight p.
  • Page 430 Operating elements for crane operation 8.1 Overview of the operating elements – For the MAXbase slewing range type Additional equipment Depending on the version, the top view (2) to (5) is shown rotated by 180°. The representation occurs in the same manner as in the RCL Monitoring à...
  • Page 431 Operating elements for crane operation 8.1 Overview of the operating elements à 1 Enter slewing range p. 8 - 130 à 2 Input front left outrigger span p. 8 - 133 à 3 Input front right outrigger span p. 8 - 133 à...
  • Page 432 Operating elements for crane operation 8.1 Overview of the operating elements Pre-selection telescoping menu 8 - 38 3 302 633 en Operating Instructions GMK5250L...
  • Page 433 Operating elements for crane operation 8.1 Overview of the operating elements Enter desired parameter à 1 Input load p. 8 - 135 à 2 Input working radius p. 8 - 135 à 3 Input main boom length p. 8 - 135 à...
  • Page 434 Operating elements for crane operation 8.1 Overview of the operating elements à Displaying the lifting capacity tables , p. 10 - 59 Lifting capacity tables menu – For the Standard slewing range type 1 Slewing range display 2 Permissible working range display I Main hoist display Limitation due to reeving II Auxiliary hoist display...
  • Page 435 Operating elements for crane operation 8.1 Overview of the operating elements Telescoping semi- automation menu à 1 Telescopic sections display p. 8 - 118 à 2 Pre-selection for all telescopic sections p. 8 - 119 à 3 Pre-selection individual telescopic sections p.
  • Page 436 Operating elements for crane operation 8.1 Overview of the operating elements Manual telescoping menu à 1 Locking status telescopic section display p. 8 - 121 à 2 Symbol lock/release telescopic section p. 8 - 121 à 3 Telescoping cylinder in the telescopic section display p.

  • Page 437: Working Range Limiter Menu Group

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.12 Working range limiter menu group à 1 Overall height menu p. 8 - 44 à 2 Working radius menu p. 8 - 45 à 3 Slewing angle menu p.
  • Page 438 Operating elements for crane operation 8.1 Overview of the operating elements Overall height menu à 1 Switching monitoring function on/off p. 10 - 142 à 2 Apply current overall height p. 10 - 136 à 3 Input maximum overall height p.
  • Page 439 Operating elements for crane operation 8.1 Overview of the operating elements Working radius menu à 1 Switching monitoring function on/off p. 10 - 142 à 2 Current working radius display p. 10 - 137 à 3 Maximum working radius display p.
  • Page 440 Operating elements for crane operation 8.1 Overview of the operating elements Slewing angle menu à 1 Switching monitoring function on/off p. 10 - 142 à 2 Maximum slewing angle A display p. 10 - 135 à 3 Current slewing angle A display p.
  • Page 441 Operating elements for crane operation 8.1 Overview of the operating elements Hoist rope travel limitation menu à 1 Switching monitoring function on/off p. 10 - 142 à 2 Input confirmation display, top p. 10 - 138 à 3 Input confirmation display, bottom p.

  • Page 442: Information 1 Menu Group

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.13 Information 1 menu group à 1 Hydraulic pressure and fuel consumption menu p. 8 - 49 à 2 Datalogger menu p. 8 - 50 8 - 48 3 302 633 en Operating Instructions GMK5250L...
  • Page 443 Operating elements for crane operation 8.1 Overview of the operating elements Hydraulic pressure and fuel consumption menu à 1 Angle gear temperature display p. 8 - 123 à 2 Slewing gear hydraulic circuit pressure display p. 8 - 123 à 3 Telescoping cylinder pressure display p.
  • Page 444 Operating elements for crane operation 8.1 Overview of the operating elements Datalogger menu à 1 Export data p. 8 - 136 à 2 Display of export progress p. 8 - 136 à 3 USB connection for data export p. 8 - 136 8 - 50 3 302 633 en Operating Instructions GMK5250L...

  • Page 445: Heating/Engine/Additional Equipment Menu Group

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.14 Heating/Engine/Additional equipment menu group à 1 Economy menu p. 8 - 52 à 2 Remote control menu p. 8 - 53 à 3 Heating/air-conditioning menu p. 8 - 54 à...
  • Page 446 Operating elements for crane operation 8.1 Overview of the operating elements Economy menu à 1 Switching off Economy mode on/off p. 8 - 86 à 2 Setting interval I p. 8 - 86 à 3 Setting interval II p. 8 - 86 à...
  • Page 447 Operating elements for crane operation 8.1 Overview of the operating elements Remote control menu à 1 Remote control menu p. 8 - 126 à 2 Remote control display p. 8 - 126 Operating Instructions GMK5250L 3 302 633 en 8 - 53...
  • Page 448 Operating elements for crane operation 8.1 Overview of the operating elements Heating/air-condi- tioning menu à 1 Outdoor temperature display p. 10 - 147 à 2 Setting the air distribution p. 10 - 148 à 3 Setting the temperature p. 10 - 147 à...
  • Page 449 Operating elements for crane operation 8.1 Overview of the operating elements Spotlights menu à 1 Switching automatic spotlights on/off p. 8 - 140 à 2 Increase the slewing speed p. 8 - 140 à 3 Reduce the slewing speed p. 8 - 140 à...

  • Page 450: Telescoping Emergency Program Menu Group

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.15 Telescoping emergency program menu group à 1 Telescoping emergency program menu p. 8 - 57 à 2 Unknown telescoping menu p. 8 - 58 à 3 Swinging the swing-away lattice emergency p.
  • Page 451 Operating elements for crane operation 8.1 Overview of the operating elements Telescoping emergency program menu XXX sec XXXX mm XXXX mm à 1 Input access code emergency program p. 14 - 29 à 2 Remaining time emergency program display p. 14 - 29 à...
  • Page 452 Operating elements for crane operation 8.1 Overview of the operating elements Unknown telescoping menu à 1 Input access code unknown telescoping p. 14 - 39 à 2 Input for telescopic section 1 p. 14 - 39 à 3 Input for telescopic section 2 p.
  • Page 453 Operating elements for crane operation 8.1 Overview of the operating elements Swinging the swing-away lattice emergency operation menu 1 Locked automatic slewing warning message Enable/disable telescoping 3 Telescoping cylinder length display 4 Extending/retracting the swivel ram à Operating Instructions Lattice Extension Operating Instructions GMK5250L 3 302 633 en 8 - 59...

  • Page 454: Settings Menu Group

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.16 Settings menu group à 1 Crane cab menu p. 8 - 61 à 2 Set display brightness and date/time menu p. 8 - 62 à 3 Switch units menu p.
  • Page 455 Operating elements for crane operation 8.1 Overview of the operating elements Crane cab menu à 1 Windscreen interval duration selection/display p. 8 - 142 à 2 Selection/display of skylight interval duration p. 8 - 142 à 3 Retract/extend step selection p.
  • Page 456 Operating elements for crane operation 8.1 Overview of the operating elements Set display bright- This is operated in the same way as in the driver's cab. ness and date/ time menu à 1 Selection setting the display brightness p. 4 - 13 à...
  • Page 457 Operating elements for crane operation 8.1 Overview of the operating elements Switch units menu 1 Display units in: – Metres – Degrees Celsius – Kilograms – Bar à p. 10 - 125 2 Display units in: – Feet – Degrees Fahrenheit –...
  • Page 458 Operating elements for crane operation 8.1 Overview of the operating elements Set control lever characteristic curve menu 1 Characteristic curve slewing gear 2 Characteristic curve telescoping mechanism 3 Characteristic curve derricking gear à 4 Characteristic curve main hoist p. 10 - 126 1) characteristic curve 5 Auxiliary hoist 1) characteristic curve...
  • Page 459 Operating elements for crane operation 8.1 Overview of the operating elements Power unit speeds menu 1 Enter slewing gear speed 2 Enter telescoping mechanism speed 3 Enter derricking gear speed à 4 Enter speed – main hoist p. 10 - 123 5 Enter speed –...

  • Page 460: Information 2 Menu Group

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.17 Information 2 menu group à 1 Operating hours menu p. 8 - 67 à 2 Engine/transmission error menu p. 8 - 68 à 3 Crane operation error menu p.
  • Page 461 Operating elements for crane operation 8.1 Overview of the operating elements Operating hours menu XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX n XXXX h XXXX h XXXX h XXXX n XXXX h...
  • Page 462 Operating elements for crane operation 8.1 Overview of the operating elements Engine/transmis- This is operated in the same way as in the driver's cab. sion error menu 1 Display of error / total errors 2 Engine symbol display 3 Transmission symbol display à...
  • Page 463 Operating elements for crane operation 8.1 Overview of the operating elements Crane operation error menu 1 Display of error / total errors 2 Error message display à 3 Acknowledge the error p. 14 - 7 4 Previous error 5 Next error Operating Instructions GMK5250L 3 302 633 en 8 - 69...
  • Page 464 Operating elements for crane operation 8.1 Overview of the operating elements Program version menu à 1 Serial number display p. 14 - 3 à 2 Program version display p. 14 - 3 8 - 70 3 302 633 en Operating Instructions GMK5250L...

  • Page 465: Operation Of Various Controls

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.18 Operation of various controls à 1 Preheating the hydraulic oil p. 8 - 123 à 2 Camera on/off p. 11 - 140 à 3 Override torque reduction p. 10 - 129 à...

  • Page 466: On The Rcl Control Unit

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.19 On the RCL control unit 1 RCL display à 2 USB connection for data export p. 8 - 136 3 No function à 4 Switch off RCL buzzer p.

  • Page 467: Menu-Independent Displays

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.20 Menu-independent displays à 1 Warning messages display p. 14 - 9 à 2 Working range limiter displays p. 10 - 132 à 3 RCL status display p. 10 - 51 Operating Instructions GMK5250L 3 302 633 en 8 - 73...

  • Page 468: Rcl - Menus

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.21 RCL – Menus Monitoring menu Depending on the version, the top view in view A is shown, or is shown rotated by 180° in view B. This operating manual shows view A in the subsequent illustrations.
  • Page 469 Operating elements for crane operation 8.1 Overview of the operating elements à 1 Display RCL code p. 10 - 45 à 1),2) 2 Current lattice extension inclination display p. 10 - 50 à 1),2) Lattice extension display – angle p. 10 - 46 à...
  • Page 470 Operating elements for crane operation 8.1 Overview of the operating elements à The same menu is displayed as shown on the CCS display; Lifting capacity p. 8 - 40. tables menu Either the Monitoring menu or the Lifting capacity table menu is displayed. The display occurs automatically.

  • Page 471: Hand-Held Controls

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.22 Hand-held controls à 1 Engine control panel p. 8 - 144 à 2 Pre-select emergency operation p. 8 - 145 à 3 Function buttons p. 8 - 145 à...
  • Page 472 Operating elements for crane operation 8.1 Overview of the operating elements Outriggers con- trol panel à 1 Front left outrigger p. 8 - 94 à 2 Current inclination display p. 8 - 103 à 3 Front right outrigger p. 8 - 94 à...

  • Page 473: Outrigger Control Units

    Operating elements for crane operation 8.1 Overview of the operating elements 8.1.23 Outrigger control units Menu-inde- This function of the illustrated buttons is the same in all the menus. This pendent function of the other buttons depends on the opened menu. buttons à...
  • Page 474 Operating elements for crane operation 8.1 Overview of the operating elements Outrigger menu 8 - 80 3 302 633 en Operating Instructions GMK5250L...
  • Page 475 Operating elements for crane operation 8.1 Overview of the operating elements Opposite means: on the side of the carrier opposite to the operator when looking at the control unit. Left and right mean: to the left or the right of the control unit. Outrigger à...
  • Page 476 Operating elements for crane operation 8.1 Overview of the operating elements Raise axle menu à 1 to 5 Pre-selection display p. 8 - 101 Directional indicator à Wheel load display, opposite p. 8 - 102 à Wheel load display, operator's side p.

  • Page 477: Brief Description Of The Operating Elements

    This section does not contain all the requirements that must be fulfilled for several operating elements to be active. If some operating elements do not work, first read the following chapters referred to at the respective places before contacting Manitowoc Crane Care 8.2.1 Definition of direction information Basic rule Direction information always depends on whether the carrier or the super- structure is being operated.

  • Page 478: General Rules For Buttons And Symbols On The Display

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.2 General rules for buttons and symbols on the display The symbols shown as an example are not present on all crane types. The following rules apply in all menus: –...

  • Page 479: Engine

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.3 Engine à Start the engine , p. 9 - 5. Side panel Ignition lock – 0 Ignition off, engine off, key can be removed – 1 Ignition on and power supply on for: instrument lighting, CCS, engine control system, RCL à...

  • Page 480: Adblue (Def) System

    Operating elements for crane operation 8.2 Brief description of the operating elements Economy menu – To open: Select and confirm symbol (1). Select symbol and confirm for: 1 Switching off Economy mode on/off 2 Set interval 1 3 Set interval 2 à...
  • Page 481 Operating elements for crane operation 8.2 Brief description of the operating elements AdBlue (DEF) system malfunction à Faults on the Adblue (DEF) system , p. 7 - 19 1 – On: Torque reduction indicator 1 – On: Reduction in torque the next time the engine is started 1 –...

  • Page 482: Seat Contact Switch And Dead Man's Switch

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.5 Seat contact switch and dead man's switch The seat contact switch and the dead man's switch are safety devices for releasing crane functions. Enabling crane functions – Sit down – seat contact switch (2) on –...

  • Page 483: Ccs Crane Control

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.6 CCS Crane control The GMK5250L truck crane is equipped with the CCS crane control system. The crane control system consists of a monitor and control unit in the driver's cab and the crane cab.
  • Page 484 Operating elements for crane operation 8.2 Brief description of the operating elements In the Menu area – For selecting and opening menus. One symbol is always selected. Select a menu 1 Turn 2 Press – The next symbol is marked. Open menu 1 Press 3 Press...
  • Page 485 Operating elements for crane operation 8.2 Brief description of the operating elements – For carrying out movements during rigging. The required element is marked e.g. outrigger cylinder (1). – For turning on/off and switching A symbol for a status is marked, e.g. symbol (2). Executing a movement –...
  • Page 486 Operating elements for crane operation 8.2 Brief description of the operating elements Exiting the menu/input mode 1 Press: – The opened menu closes – the menu from the next higher level is opened – Input mode is deactivated. Overview menu groups 1 Press: –...
  • Page 487 Operating elements for crane operation 8.2 Brief description of the operating elements Display temperature warning display The temperature of the control unit is measured by an internal sensor. – blue, flashing: Temperature too low – display will not be switched on Temperature too high: –...

  • Page 488: Outrigger - Hand-Held Control

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.7 Outrigger – hand-held control à Extending/retracting outrigger beams , p. 11 - 45 à Extending/retracting supporting cylinders , p. 11 - 53 à All directional information refers to the carrier; p.
  • Page 489 Operating elements for crane operation 8.2 Brief description of the operating elements Pre-select high-speed/normal speed mode – Pre-select: – Press button once – lamp (1) lights up – High-speed mode pre-selection on – Press button once – lamp (1) goes out – Normal speed pre-selection on Function buttons There are four button combinations to execute the pre-selected functions.

  • Page 490: Outrigger - Crane Cab

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.8 Outrigger – crane cab à Extending/retracting outrigger beams , p. 11 - 45 à Extending/retracting supporting cylinders , p. 11 - 53 The display fields must be switched on for crane operation – in the driver's cab, in the Settings submenu on the CCS display.
  • Page 491 Operating elements for crane operation 8.2 Brief description of the operating elements Outrigger control units on/off – To switch on: Select symbol (2) and confirm – symbol (1) is grey – To switch off: Select symbol (1) and confirm – symbol (2) is grey à...

  • Page 492: Outrigger - Control Units

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.9 Outrigger – control units à Extending/retracting outrigger beams , p. 11 - 45 à Extending/retracting supporting cylinders , p. 11 - 53 à All directional information refers to the carrier; p.
  • Page 493 Operating elements for crane operation 8.2 Brief description of the operating elements Menu selection Selection: Press the button – the next menu is shown on the Outrigger display Pre-select high-speed/normal speed mode 1 Pre-select: Press button – high-speed mode pre-selection on 2 Pre-select: Press button –...
  • Page 494 Operating elements for crane operation 8.2 Brief description of the operating elements Operating the right outriggers (next to control unit) Operation is the same as on the button unit for Outriggers next to the control unit . Extending/retracting all supporting cylinders Button (3) or (4) is pressed.

  • Page 495: Raise Axle

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.10 Raise axle à Operating the axle raising system , p. 11 - 63 Raise axle menu The suspension is switched off (locked). – To open: Press button (2) repeatedly until display (1) appears. The operating elements for raising the axles are only active when the Raise axle menu is open.
  • Page 496 Operating elements for crane operation 8.2 Brief description of the operating elements Lifting/lowering wheels The axle load on the pre-selected wheels lies in the permissible range. The horn sounds when a button is pressed. 1 Raise: Press the button – the selected axles are raised and the truck crane is lowered 2 Lower: Press the button –...

  • Page 497: Inclination Indicators

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.11 Inclination indicators à Inclination indicators , p. 11 - 58 Current inclination display A On the hand-held control B On the outrigger control units C In the Outrigger menu D In the Monitoring menu 1 Inclination indicator 2 Measuring range display...

  • Page 498: Outrigger Pressure Displays

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.12 Outrigger pressure displays à Outrigger pressure display , p. 11 - 65 Outrigger pressure display A In the Outrigger menu B In the Monitoring menu C On the outrigger control units –...

  • Page 499: Counterweight Menu

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.14 Counterweight menu à Rigging/unrigging the counterweight , p. 11 - 67, Counterweight à Counterweight hoist unit , p. 11 - 85. submenu – To open: Select and confirm symbol (1) Rigging position display 1 white –...
  • Page 500 Operating elements for crane operation 8.2 Brief description of the operating elements Automatic mode rigging – Display Yellow: Recognition that the counterweight is rigged Flashing: Automatic mode on Grey Automatic mode cancelled or No recognition that counterweight is rigged The superstructure is within the rigging range, the slewing gear is switched on and the lifting cylinders are retracted –...
  • Page 501 Operating elements for crane operation 8.2 Brief description of the operating elements Lifting cylinder position display The current position of the counterweight lift- ing cylinders is shown by different symbols: 1 green – extended 2 green – retracted 3 yellow – intermediate position 4 violet –...
  • Page 502 Operating elements for crane operation 8.2 Brief description of the operating elements Slewing gear display à Identical to the display in the Slewing gear/House lock submenu ; p. 8 - 113. Current slewing angle display à Identical to the display in the Slewing gear/House lock submenu ; p.

  • Page 503: Main Hoist

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.15 Main hoist à Main hoist , p. 10 - 75. Control panels Main hoist on/off There is a lamp in the button. – Press once: – Lamp bright – main hoist on –...
  • Page 504 Operating elements for crane operation 8.2 Brief description of the operating elements High speed monitoring for the hoist – On: High-speed mode on – Off: High-speed mode off à p. 10 - 114 Lift/lower the hoist display – Symbol (1): Raise –...

  • Page 505: Auxiliary Hoist

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.16 Auxiliary hoist à Auxiliary hoist , p. 10 - 79. Control panels Auxiliary hoist on/off There is a lamp in the button. – Press once: – Lamp bright – auxiliary hoist on –...
  • Page 506 Operating elements for crane operation 8.2 Brief description of the operating elements High speed monitoring for the hoists – On: High-speed mode on – Off: High-speed mode off à p. 10 - 114 Lift/lower the hoist display – Symbol (1): Raise –...

  • Page 507: Slewing Gear

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.17 Slewing gear à Slewing gear , p. 10 - 115. Control panels Slewing gear on/off There is a lamp in the button. – Press once: – Lamp bright – slewing gear on, Slewing gear brake released –...
  • Page 508 Operating elements for crane operation 8.2 Brief description of the operating elements CCS display Power units display – Green: Slewing gear on – Red: Slewing gear off Slewing gear brake applied/released display 1 On: Slewing gear brake applied 1 Off: Slewing gear brake released à...

  • Page 509: Derricking Gear

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.18 Derricking gear à Derricking gear , p. 10 - 85. Control panels Derricking gear on/off There is a lamp in the button. – Press once: – Lamp bright – derricking gear on, Power units with the same control lever configuration –...
  • Page 510 Operating elements for crane operation 8.2 Brief description of the operating elements CCS display Power units display – Green: Derricking gear on – Red: Derricking gear off High-speed mode inspection derricking gear – On: High-speed mode on – Off: High-speed mode off à...

  • Page 511: Telescoping Mechanism

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.19 Telescoping mechanism à Telescoping mechanism , p. 10 - 89. Control panels Telescoping mechanism on/off There is a lamp in the button. – Press once: – Lamp bright – telescoping mechanism on, Power units with the same control lever configuration –...
  • Page 512 Operating elements for crane operation 8.2 Brief description of the operating elements Telescoping semi- automation menu To open: Select symbol (1) and confirm – menu is opened Telescope diagram display Current relation of the telescopic sections to each other – section of top view.
  • Page 513 Operating elements for crane operation 8.2 Brief description of the operating elements Current telescope status display Extended length of the telescopic sections in percentage 1 - 6 Display for telescopic sections 1 to 6 Pre-selection for all telescopic sections 1 Pre-selection telescoping 0% 2 Pre-selection telescoping 50% 3 Pre-selection telescoping 100% Pre-selection individual telescopic sections...
  • Page 514 Operating elements for crane operation 8.2 Brief description of the operating elements Manual telescoping menu To open: Select symbol (1) and confirm – menu is opened Telescoping cylinder locked/released – Display Yellow: Locking pins intermediate position Green: Telescoping cylinder locked Red: Telescoping cylinder unlocked Lock/unlock telescoping cylinder...
  • Page 515 Operating elements for crane operation 8.2 Brief description of the operating elements Lock/release telescopic section – Display Yellow: Locking pins intermediate position Green: Telescopic section locked Red: Telescopic section unlocked – To lock: – The telescoping cylinder is locked: Select symbol (2) and confirm – telescopic section locked –...
  • Page 516 Operating elements for crane operation 8.2 Brief description of the operating elements Telescoping cylinder in the telescopic section display Displayed telescopic section, e.g. telescopic section 1 Telescoping direction display 1 Start with Retract 2 Start with Extend à p. 10 - 110 Telescope diagram display Current relation of the telescopic sections to each other –...

  • Page 517: Hydraulic System

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.20 Hydraulic system Inclining the crane cab – Press down: incline to the front – Press up: incline to the rear à p. 10 - 121 In Information menu 1 Angle gear oil temperature Current pressure in bar for movements of: 2 Slewing gear...

  • Page 518: Superstructure Lock/House Lock Menu

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.21 Superstructure lock/house lock menu – To open: Select symbol (1) and confirm – menu is opened à Locking/unlocking the superstructure , p. 10 - 15. Superstructure lock Locking status displays The current position of the locking pin is shown by different symbols:...
  • Page 519 Operating elements for crane operation 8.2 Brief description of the operating elements Current slewing angle display Position 0° to the rear – locking point 0°: Position 180° to the front – locking point 180°: + 0.1 to +180.0°: Turned to the right from 0° - 0.1 to -179.9°: Turned to the left from 0°...

  • Page 520: Remote Control

    Operating elements for crane operation 8.2 Brief description of the operating elements House lock on/off To switch on: Symbol (1) – Pin extends To switch off: Symbol (2) – Pin retracts à p. 10 - 17 8.2.22 Remote control Operating with the remote control is only enabled for the Standard slewing range type.

  • Page 521: Rated Capacity Limiter (Rcl)

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.23 Rated capacity limiter (RCL) CCS display In the Start menu For the Standard slewing range type Only one slewing range is displayed 1 360° slewing range 2 Restricted slewing range, e.g. ±30° 3 Working position, e.g.
  • Page 522 Operating elements for crane operation 8.2 Brief description of the operating elements Maximum permissible working radius display Shows the maximum permissible working radius (5) for each slewing range. 1 Display area – always corresponds to the largest maximum working radius (5) 2 Maximum permissible working radius in the corresponding slewing range with the currently lifted load...
  • Page 523 Operating elements for crane operation 8.2 Brief description of the operating elements Maximum permissible speed display Separate displays are provided for each direc- tion of movement. 1 Slew to the left 2 Slew to the right 3 Lower the main hoist 4 Lift the main hoist 5 Lower the auxiliary hoist 6 Lifting the auxiliary hoist...
  • Page 524 Operating elements for crane operation 8.2 Brief description of the operating elements In the Enter rigging mode/telescope status menu Select and confirm the symbol (1) – the menu opens, and opens automati- cally after Ignition on Enter slewing range In input mode Select slewing range symbol and confirm –...
  • Page 525 Operating elements for crane operation 8.2 Brief description of the operating elements Reeving input mode display 1 Main hoist 2 Auxiliary hoist Orange: Grey: à Enter rigging mode , p. 10 - 32 Enter reeving 1 Main hoist In input mode – select and confirm current reeving 2 Auxiliary hoist –...
  • Page 526 Operating elements for crane operation 8.2 Brief description of the operating elements Boom system display A Main boom display B Lattice extension display C Heavy load lattice extension display 1 Angle of the lattice extension display (for inclinable lattice extension) Boom system entry For the Standard slewing range type only.
  • Page 527 Operating elements for crane operation 8.2 Brief description of the operating elements Accept the measured outrigger span Select and confirm – the outrigger span provided by the outrigger width monitoring is adopted and shown on the Enter outrigger span display; à...
  • Page 528 Operating elements for crane operation 8.2 Brief description of the operating elements Outrigger span monitoring display (standard) Query after confirming the rigging mode. A Measured outrigger width = required width B Measured outrigger span ≠ of required span (query menu) 2 Required outrigger width –...
  • Page 529 Operating elements for crane operation 8.2 Brief description of the operating elements In the Pre-selection telescoping menu à Pre-selecting telescoping , p. 10 - 40 Enter desired parameter In input mode – select and confirm parame- ters (1), (2). 1 Selection of numerical values 2 Selection by marking the segments –...
  • Page 530 Operating elements for crane operation 8.2 Brief description of the operating elements In the Datalogger menu à Datalogger , p. 10 - 68 – To open: Select and confirm symbol (1) USB connection for data export 1 Connect the USB stick – the symbol for the export is activated Export data Can only be selected when a USB stick is connected to the RCL control unit.
  • Page 531 Operating elements for crane operation 8.2 Brief description of the operating elements RCL override – This version only applies to RCL programming as per EN 13000. à version A For other RCL programming; p. 8 - 138. RCL override RCL shutdown overridden – crane functions 1 Press once: enabled up to 110% utilisation –...
  • Page 532 Operating elements for crane operation 8.2 Brief description of the operating elements RCL override – This point only applies to RCL programming deviating from EN 13000. à version B For RCL programming in accordance with EN 13000; p. 8 - 137. Overriding the RCL in an emergency RCL shutdown overridden –...

  • Page 533: Electrical System

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.24 Electrical system Voltage warning lamp – Display symbol: Engine on – power failure – switch off engine – Off: Engine on – no malfunction à p. 9 - 6 8.2.25 Lighting, windscreen wiper/washing system Lighting...
  • Page 534 Operating elements for crane operation 8.2 Brief description of the operating elements Slewable spotlight on/off – To switch on: Push down – lamp in the button on – To switch off: Push up – lamp in the button off à p.
  • Page 535 Operating elements for crane operation 8.2 Brief description of the operating elements Reading lamp 1 On 2 Off Windscreen wiper/washing system Windscreen wiper on/off – Off: mid-position – Interval: Push up – wiper goes to end position – Continuous Push down operation: Roof window wiper on/off –...
  • Page 536 Operating elements for crane operation 8.2 Brief description of the operating elements Crane cab menu To open: Select symbol (1) and confirm – menu is opened Adjusting the wiper stroke interval 1 Windscreen wiper selection, display (5) 2 Skylight wiper selection, display (6) 7 Changing the interval duration Wiper interval in seconds for 3 Windscreen wiper...

  • Page 537: Hand-Held Control

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.26 Hand-held control Sockets for The following applies to all sockets: hand-held control – Pull plug: Engine off – ignition off – Insert plug: Ignition on à p. 11 - 21 The hand-held control is only active when it is connected to the sockets (1) to (4).
  • Page 538 Operating elements for crane operation 8.2 Brief description of the operating elements à Starting the engine – with the hand-held control , p. 9 - 8 Engine control panel 1 Voltage monitoring – On: Ignition on – Off: Switch the ignition off 2 CAN monitoring –...
  • Page 539 Operating elements for crane operation 8.2 Brief description of the operating elements à Outriggers control panel , p. 8 - 78. Outriggers Brief description; control panel Pre-select emergency operation 1 Main hoist 2 Telescoping mechanism 3 Derrick lattice extension 4 Auxiliary hoist 5 Derricking gear 6 Slewing gear Lattice extension –...
  • Page 540 Operating elements for crane operation 8.2 Brief description of the operating elements Pre-selected power unit Telescoping Derricking Slewing Lattice Button Hoists mechanism gear gear extension combination from the from the None None Lower cabin cabin Retract Raise None Raise Raise Slew to the None None...

  • Page 541: Windows, Doors, Keys

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.27 Windows, doors, keys Windows The handles on the windscreen and the rear window have the same function. Open window (A) • Turn both handles (1) inward. • Push the window forward.
  • Page 542 Operating elements for crane operation 8.2 Brief description of the operating elements Crane cab door From outside Unlocking • Turn the key in direction A. Locking • Turn the key in direction B. Open/close • Pull the handle (1). • Slide the door.
  • Page 543 Operating elements for crane operation 8.2 Brief description of the operating elements Keys Different keys are supplied. 1 Crane cab door lock 2 Crane cab ignition lock 3 Storage compartment 4 Control units for outriggers 5 Windscreen washing system reservoir 6 Boom floating position lock 7 Slewing gear freewheel lock 8 Key-operated override switch...

  • Page 544: Diagnostics

    Operating elements for crane operation 8.2 Brief description of the operating elements 8.2.28 Diagnostics The diagnostics connections may only be operated by the service personnel. The following connections are below the cover (4) 1 CCS diagnostics – (serial interface) 2 CCS diagnostics – CAN bus 3 RCL diagnostics Additional diagnostic and service connections are present on the CCS control unit (5).

  • Page 545: Starting/Switching Off The Engine - For Crane Operation

    Starting/switching off the engine – for crane operation 9.1 When starting the engine for the first time in the day Starting/switching off the engine – for crane operation You must start the engine from the crane cab for crane operation. If the engine has been started from the carrier, then you must shut it down in the carrier and switch off the ignition before crane operation.

  • Page 546: Checking The Fuel Level And Adblue (Def) Level

    Starting/switching off the engine – for crane operation 9.1 When starting the engine for the first time in the day 9.1.1 Checking the fuel level and AdBlue (DEF) level • Check the fuel level, and the AdBlue (DEF) level if necessary, before starting the engine.

  • Page 547: Checks Before Starting The Engine

    Starting/switching off the engine – for crane operation 9.1 When starting the engine for the first time in the day 9.1.2 Checks before starting the engine At the hydraulic The valve on the hydraulic tank must be open before starting the engine. tank Risk of damage to the hydraulic pumps! You may only start the engine when the valve on the hydraulic tank is open!

  • Page 548: Switch On The Ignition

    Starting/switching off the engine – for crane operation 9.1 When starting the engine for the first time in the day Checking the hand-held control The hand-held control must be removed for crane operation from the crane cab. • Check whether bridging plugs (1) to (4) are inserted in all the sockets; à...

  • Page 549: Display - Setting The Brightness

    Starting/switching off the engine – for crane operation 9.1 When starting the engine for the first time in the day 9.1.4 Display – setting the brightness • Open the Settings menu (1). à This is operated in the same way as in the driver's cab; p.

  • Page 550: Inspections After Starting The Engine

    Starting/switching off the engine – for crane operation 9.1 When starting the engine for the first time in the day 9.1.6 Inspections after starting the engine • Check the display (1) on the CCS control unit immediately after starting the engine. When a symbol is displayed in the display à...

  • Page 551: Set Idling Speed

    Starting/switching off the engine – for crane operation 9.1 When starting the engine for the first time in the day 9.1.7 Set idling speed à • Start the engine; p. 9 - 5. • Open the start menu – button (1). The display (2) shows the current engine speed You can increase the idling speed for crane operation.

  • Page 552: Starting The Engine - With The Hand-Held Control

    Starting/switching off the engine – for crane operation 9.2 Starting the engine – with the hand-held control Starting the engine – with the hand-held control Prerequisites You can only start the engine, if: à – The bridging plug is inserted in all unneeded sockets; p.

  • Page 553: Switching Off The Engine

    Starting/switching off the engine – for crane operation 9.3 Switching off the engine Switching off the engine 9.3.1 During normal operation, with the ignition lock / with the hand-held control Risk of accidents due to suspended loads! Never switch off the engine whilst a load is suspended. You must have the control levers at hand in order to intervene at any time.

  • Page 554: In Emergencies, With The Emergency Stop Switches

    Starting/switching off the engine – for crane operation 9.3 Switching off the engine 9.3.2 In emergencies, with the emergency stop switches Risk of overloading if used improperly! Use the emergency stop switches only in an emergency, i.e. if the crane functions no longer respond to the control levers.

  • Page 555: Crane Operation

    Crane operation 10.1 Before operating the crane Crane operation 10.1 Before operating the crane 10.1.1 CHECKLIST: Checks before operating the crane This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there. This checklist only applies to working with a rigged truck crane (supported and rigged with counterweight).
  • Page 556 Crane operation 10.1 Before operating the crane à 3. – Switch on the cameras for crane operation; p. 11 - 137. à – Adjust the slewable spotlights if necessary; p. 10 - 127. à 4. Crane cab heater – check the fuel level; p.
  • Page 557 Crane operation 10.1 Before operating the crane à 9. Check the position of the hoist ropes; p. 10 - 6. 10. Compare current rigging mode with the RCL display – enter and con- à firm current rigging mode, if necessary; p.
  • Page 558 Crane operation 10.1 Before operating the crane à 14. Check hydraulic oil temperature, preheat if necessary; p. 10 - 14. à 15. Adjust the brightness of the CCS display as required; p. 9 - 5. Additional information on inspections during crane operation, on permissi- ble working positions and on how to operate the individual power units;...

  • Page 559: Check The Condition Of The Truck Crane

    Crane operation 10.1 Before operating the crane 10.1.2 Check the condition of the truck crane Fuel tank auxiliary Use the same fuel as for the engine or use EL heating oil for refuelling. heater Danger of fire due to flammable gases! Turn off the engine and heating systems before refuelling.
  • Page 560 Crane operation 10.1 Before operating the crane Checking the position of the hoist ropes Risk of crushing due to turning rope drum! Keep away from the rope drum while it is turning. This will prevent your limbs from being drawn in or crushed. •...
  • Page 561 Crane operation 10.1 Before operating the crane • Checking the Check the following functions and have faulty parts repaired. electrical system – Spotlights, – Air traffic control light, rotating beacons – Windscreen wipers, windscreen washing system, – Horn. Operating Instructions GMK5250L 3 302 633 en 10 - 7...

  • Page 562: Adjusting The Crane Cab Seat And Front Control Panel

    Crane operation 10.1 Before operating the crane 10.1.3 Adjusting the crane cab seat and front control panel Crane cab seat You can adjust the crane cab seat to your height. Version 1 1 Control panel right – height 2 Control panel left – height 3 Back rest –...
  • Page 563 Crane operation 10.1 Before operating the crane Front panel You can adjust the height and inclination. • Release the handle (1) – anti-clockwise. • Adjust the front panel to suit your requirements. • Turn the handle (1) firmly – clockwise. Operating Instructions GMK5250L 3 302 633 en 10 - 9...

  • Page 564: Checking The Safety Equipment

    It is prohibited to operate the crane with safety devices that are faulty, overridden or out of service! Have faulty safety devices repaired immediately by Manitowoc Crane Care • Rated capacity Switch on the rated capacity limiter (RCL), do all of the checks and enter limiter the current rigging mode;...
  • Page 565 Repeat the checks with the emergency stop switches (1) and (2). If the emergency off switch is not working correctly, do not start crane operation but notify Manitowoc Crane Care Operating Instructions GMK5250L 3 302 633 en 10 - 11...
  • Page 566 With the control lever actuated, stand up and check whether the crane movement comes to a standstill within approx. 3 seconds. If the dead man's switch system is not working correctly, do not start crane operation but notify Manitowoc Crane Care 10 - 12 3 302 633 en Operating Instructions GMK5250L...

  • Page 567: Earthing The Load

    Crane operation 10.1 Before operating the crane 10.1.5 Earthing the load à Even if the truck crane is already earthed ( p. 11 - 13), the load may become charged with static electricity. For example, if a hook block with synthetic sheaves or non-conducting sling gear is used.

  • Page 568: Preheating The Hydraulic Oil

    Crane operation 10.1 Before operating the crane 10.1.6 Preheating the hydraulic oil It may take some time for the solenoid valves to be switched or the power units may be started abruptly if the oil is cold. The current hydraulic oil temperature is displayed in the start menu. For crane operation with loads and without speed limitation, the hydraulic oil temperature must be at 10 °C (50 °F).

  • Page 569: Locking/Unlocking The Superstructure

    Crane operation 10.1 Before operating the crane 10.1.7 Locking/unlocking the superstructure To lock, a pin can extend on the turntable and engage in two locking points on the carrier. Locking points The locking points are at 0° and at 180 °C. •...
  • Page 570 The display changes from symbol (1) to sym- bol (2) and shows symbol (6) when the super- structure is locked. If the error symbol (3) is displayed, contact Manitowoc Crane Care Unlocking the The RCL shutdown procedure will be triggered and slewing disabled if you superstructure unlock the superstructure when an RCL code for 0°...

  • Page 571: Switching The Houselock On/Off

    Crane operation 10.1 Before operating the crane 10.1.8 Switching the houselock on/off If the truck crane is equipped with a houselock, the turntable can be locked in the entire slewing range. For locking, a pin extends and blocks the slew- ing gear.
  • Page 572 Crane operation 10.1 Before operating the crane Switching on the houselock • Select the symbol (5). • Press the button until the symbol (4) is dis- played – Houselock switched on . The display first shows the symbol (1), then (2) and then shows the symbol (4) when the houselock is switched on.
  • Page 573 Crane operation 10.1 Before operating the crane • Switching off the Check that the slewing gear is switched off, and switch if off if necessary; à Switching off the slewing gear , p. 10 - 17. houselock Risk of damage during slewing! Always switch off the slewing gear before you operate the houselock.
  • Page 574 Crane operation 10.1 Before operating the crane Blank page 10 - 20 3 302 633 en Operating Instructions GMK5250L...

  • Page 575: Standard Slewing Range Type

    Crane operation 10.2 Standard slewing range type 10.2 Standard slewing range type The MAXbase slewing range type is available in the case of additional equip- à MAXbase slewing range type , p. 10 - 23. ment; The Standard slewing range type is always available. The supplied lifting capacity tables with symmetrical outrigger spans apply.
  • Page 576 Crane operation 10.2 Standard slewing range type Blank page 10 - 22 3 302 633 en Operating Instructions GMK5250L...

  • Page 577: Maxbase Slewing Range Type

    Crane operation 10.3 MAXbase slewing range type 10.3 MAXbase slewing range type This slewing range type is available in addition to the Standard slewing à Standard slewing range type , p. 10 - 21. You must decide range type; between the two slewing range types when entering the rigging mode. Lifting capacity tables with different, variable outrigger spans are available for the MAXbase slewing range type.

  • Page 578: Specifications In The Lifting Capacity Tables

    Crane operation 10.3 MAXbase slewing range type 10.3.1 Specifications in the lifting capacity tables The specified lifting capacities are only enabled for specific slewing ranges. The lifting capacity table contains a direction specification for the enabled slewing range, which is assigned to a superstructure position. Positional Superstructure reference...
  • Page 579 Crane operation 10.3 MAXbase slewing range type 10.3.2 Enabled slewing ranges The enabled angular ranges around the starting point are specified in the lifting capacity table . This section provides an overview of where the enabled slewing ranges begin and end for each slewing angle. Smallest individual width 3.900 m (12.8 ft) This case applies only to a symmetrical outrigger span with a span of 7.800 m (25.6 ft).
  • Page 580 Crane operation 10.3 MAXbase slewing range type Smallest individual width 2.955 m (9.7 ft) This case applies when one or more outrigger beams is extended to a span of 2.955 m (9.7 ft) and all other outrigger beams are extended to larger spans.
  • Page 581 Crane operation 10.3 MAXbase slewing range type Smallest individual width 1.355 m (4.4 ft) This case applies when one outrigger beam is extended to a span of 1.355 m (4.4 ft) and all other outrigger beams are extended to larger spans. Positional reference Angular range Enabled slewing range...

  • Page 582: Lifting Capacities And Slewing Ranges For Outrigger Spans Without Separate Lifting Capacity Tables

    Crane operation 10.3 MAXbase slewing range type 10.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables In the case of outrigger spans where the opposing outrigger beams at the right and left sides are extended to different lengths, lifting capacity tables are only available for combinations where the outrigger span at the right side is greater than at the left side.

  • Page 583: Operation Of The Rated Capacity Limiter

    Crane operation 10.4 Operation of the rated capacity limiter 10.4 Operation of the rated capacity limiter The rated capacity limiter is abbreviated to RCL (Rated-Capacity-Limiter) in these operating instructions. If the truck crane's current rigging mode is registered properly, the RCL will prevent the permissible lifting capacity from being exceeded and the truck crane from being overloaded.

  • Page 584: Switch On The Rcl

    Risk of accidents if the safety devices are faulty! If the lamps or buzzer fail, notify and have the error Manitowoc Crane Care corrected. In the meantime, pay particular attention to the lamps in the event of a failure of the buzzer tone and vice versa.
  • Page 585 Crane operation 10.4 Operation of the rated capacity limiter Temperature on the display The brightness is reduced automatically if the temperature at the display is too high. Do not cover the sensors (1) and keep them clean to avoid contamination that can affect the brightness adjustment.

  • Page 586: Enter Rigging Mode

    Crane operation 10.4 Operation of the rated capacity limiter 10.4.2 Enter rigging mode Notes on Input You can enter the rigging mode for various different purposes. – Entry for crane operation You enter the current rigging mode, select a telescope status according to the lifting capacity table and confirm the rigging mode to enable the crane functions.
  • Page 587 Crane operation 10.4 Operation of the rated capacity limiter Possible types are the Standard slewing range type and, with the corre- Enter the slewing sponding equipment, the MAXbase slewing range type. range type Different lifting capacity tables apply depending on the entered slewing range type and these then influence further input of the rigging mode.
  • Page 588 Crane operation 10.4 Operation of the rated capacity limiter For the Standard slewing range type • Select and confirm the display (1). • Select and confirm the symbol for the desired slewing range. 2 360° slewing range 3 Working position 0°to the rear 4 Limited slewing range 5 Working position –...
  • Page 589 Crane operation 10.4 Operation of the rated capacity limiter The displayed menu depends on the slewing range type. A Menu for Standard B Menu for MAXbase The selection is not restricted when you adhere to this sequence when entering the data. 1 Slewing range–...
  • Page 590 Crane operation 10.4 Operation of the rated capacity limiter Outrigger span You can adopt the outrigger span provided by the outrigger width monitor- ing or manually enter the outrigger span. Adopt the outrigger span • Select and confirm the symbol (2). The outrigger span provided by the outrigger width monitoring is adopted and shown on the current display (1).
  • Page 591 Crane operation 10.4 Operation of the rated capacity limiter Enter outrigger span ( MAXbase ) The outrigger spans are entered as individual widths. If the lifting capacity table specifies an overall width then select the associated individual width. Overall width Individual width 7.800 m (25.6 ft) 3.900 m (12.8 ft)
  • Page 592 Crane operation 10.4 Operation of the rated capacity limiter Counterweight • Select and confirm the display (1). • Select the rigged counterweight combina- tion, e.g. 16.5 t. • Confirm the selection. The display (2) shows the entered counter- weight combination. Boom system For the Standard slewing range type only.
  • Page 593 Crane operation 10.4 Operation of the rated capacity limiter The confirmed boom system (1) or (2) is displayed. Reeving • (A) – Select and confirm the display for the hoist to be used for lifting the load, e.g. display (1) for the main hoist – symbol (3) is orange.

  • Page 594: Pre-Selecting Telescoping

    Crane operation 10.4 Operation of the rated capacity limiter You must enter the RCL code for the rigging mode according to the lifting Entering the capacity table . RCL code • Refer to the lifting capacity table for the cur- rent rigging mode.

  • Page 595: Confirm The Rigging Mode And Lifting Capacity Table

    Crane operation 10.4 Operation of the rated capacity limiter 10.4.4 Confirm the rigging mode and lifting capacity table You must confirm the rigging mode together with the display lifting capac- ity table before commencing crane operation. Some parts of the procedure are different, depending on the entered slewing range type.
  • Page 596 Crane operation 10.4 Operation of the rated capacity limiter • Select and confirm the symbol (1). If the rigging mode is permissible The rigging mode is accepted together with the display lifting capacity table. The RCL display shows the Monitoring menu. The CCS display shows the Start menu .
  • Page 597 Crane operation 10.4 Operation of the rated capacity limiter Risk of accident due to incorrectly supported truck crane! A shutdown is not initiated as standard when an outrigger span monitoring error message is issued. When an error message is displayed, compare the rigged outrigger span with the required outrigger span and rig the required outrigger span.
  • Page 598 Crane operation 10.4 Operation of the rated capacity limiter • Select and confirm the symbol (1). If the rigging mode is permissible The rigging mode is accepted together with the display lifting capacity table. The RCL display shows the Monitoring menu. The CCS display shows the Start menu .

  • Page 599: Checks Before Operating The Crane

    Crane operation 10.4 Operation of the rated capacity limiter 10.4.5 Checks before operating the crane Monitoring menu Crane operation is only enabled when the Monitoring menu is open. The menu is opened and exited automatically only, as a reaction to com- mands on the CCS display.
  • Page 600 Crane operation 10.4 Operation of the rated capacity limiter Boom system display Shows the boom system corresponding to the confirmed rigging mode. A Main boom B Swing-away lattice extension / boom extension C Heavy load lattice extension For the Standard slewing range type only. The lattice extension must be electrically connected.
  • Page 601 Crane operation 10.4 Operation of the rated capacity limiter Display of reeving used 1 Main hoist 2 Auxiliary hoist Orange: Used Grey: Not used The value on the Maximum load display applies to this reeving. à You may need to switch over the display if necessary; p.
  • Page 602 Crane operation 10.4 Operation of the rated capacity limiter Risk of accidents due to incorrectly entered reeving! Check the displayed reeving after each switch over and enter the current reeving if necessary. In this way, you prevent the RCL from making calculations based on an incorrect reeving value and the truck crane from becoming overloaded or from overturning.

  • Page 603: Displays During Crane Operation

    Crane operation 10.4 Operation of the rated capacity limiter 10.4.6 Displays during crane operation Various different information is shown on the RCL display and CCS display. This section describes only the displays that change during crane operation. On the RCL All displays are shown in the Monitoring menu.
  • Page 604 Crane operation 10.4 Operation of the rated capacity limiter Status display for current main boom angle Shows the current main boom angle in relation to the horizontal. Angles below the horizontal are displayed with a minus sign, e.g. - 3°. A luffing jib is connected.
  • Page 605 Crane operation 10.4 Operation of the rated capacity limiter Maximum load display Shows the maximum load that can be lifted in the current rigging mode with the current working radius. Values are displayed in tons (t) or in pounds (lbs) – for the confirmed rigging mode.
  • Page 606 Crane operation 10.4 Operation of the rated capacity limiter Telescoping cylinder position display The bar (2) shows the telescoping length of the telescoping cylinder – the total bar length corresponds to 100%. Telescoping direction display The display is only active when telescoping with teleautomation and shows the direction in which you must move the control lever for each respective telescoping direction.
  • Page 607 Crane operation 10.4 Operation of the rated capacity limiter On the CCS After confirming a permissible rigging mode, the Start menu opens display automatically. Standard slewing range type à If the MAXbase slewing range type has been entered; p. 10 - 55. The RCL display differs according to the confirmed slewing range.
  • Page 608 Crane operation 10.4 Operation of the rated capacity limiter Limited slewing range The diagram (1) shows the enabled slewing range and the slewing range limits (3), e.g. +30° and -30°. – When telescoping or derricking The diagram (1) remains at the current posi- tion.
  • Page 609 Crane operation 10.4 Operation of the rated capacity limiter MAXbase slewing range type à If the Standard slewing range type has been entered; p. 10 - 53. Display of the slewing ranges The RCL display represents the four enabled slewing ranges in a diagram with four regions.
  • Page 610 Crane operation 10.4 Operation of the rated capacity limiter To enable the slewing movement, you must reduce the working radius correspondingly, e.g. to 16 m (52.5 ft) for slewing into slewing range – When telescoping or derricking The diagram remains at the current posi- tion.

  • Page 611: Rcl Early Warning

    Crane operation 10.4 Operation of the rated capacity limiter 10.4.7 RCL early warning If about 90% of the maximum permissible load is exceeded, an RCL early warning will be issued. – An intermittent buzzer tone sounds. After five seconds, you can switch off the buzzer tone using button (3) or (4).

  • Page 612: Rcl Shutdown

    Crane operation 10.4 Operation of the rated capacity limiter 10.4.8 RCL shutdown There are different types of RCL shutdowns – shutdown due to overload, à – Shutdown due to an error; p. 14 - 7. Shutdown due If approx. 100% of the maximum permissible load is exceeded, shutdown to overload will occur due to overload.

  • Page 613: Displaying The Lifting Capacity Tables

    Crane operation 10.4 Operation of the rated capacity limiter The crane movements are released when you have left the shutdown area – lamps (1) and (2) go out. 10.4.9 Displaying the lifting capacity tables Open menu • Open the lifting capacity table menu (1) on the CCS control unit. Exiting the menu •...
  • Page 614 Crane operation 10.4 Operation of the rated capacity limiter Limitation due to reeving If the maximum load is limited due to the confirmed reeving then the disabled range is marked. I Display for main hoist, e.g. maximum load 12 t II Display for auxiliary hoist, e.g.
  • Page 615 Crane operation 10.4 Operation of the rated capacity limiter à MAXbase slewing If the Standard slewing range type has been entered; p. 10 - 59. range type Permissible working range display The displays apply to the confirmed rigging mode. 1 Slewing range display – four slewing ranges, marked in colour 2 Display of permissible working ranges –...
  • Page 616 Crane operation 10.4 Operation of the rated capacity limiter When slewing The symbol (1) for the superstructure always points upwards and does not move. The symbol (2) for the carrier rotates together with the display of the slewing range division to the position corresponding to the slewing angle.
  • Page 617 Crane operation 10.4 Operation of the rated capacity limiter 10.4.10 RCL override – version A This section applies only when the supplied lifting capacity table contains the entry EN 13000 in the header (1). à RCL override – version B , p. 10 - 67. In the case of other entries;...
  • Page 618 Crane operation 10.4 Operation of the rated capacity limiter When rigging For rigging work, you can: à – override the lifting limit switch; p. 10 - 83 – override the RCL and thus enable a degree of utilisation of up to 110%. Risk of accidents if the RCL is overridden! It is not permitted to work with an overridden RCL! Use this type of override only for rigging.
  • Page 619 Crane operation 10.4 Operation of the rated capacity limiter To raise the boom You can release the raise boom function for derricking again within the permitted working range. This function is only active if the current degree of utilisation lies above 100% and the crane movements are switched off.
  • Page 620 Crane operation 10.4 Operation of the rated capacity limiter In emergencies During this type of override, the complete shutdown of the RCL is cancelled and no monitoring takes place. Risk of accidents due to overridden or faulty RCL! It is not permitted to work with an overridden or faulty RCL! Set down the load immediately and stop operating the crane if the RCL is faulty! You may only override the RCL if it becomes absolutely necessary in the...

  • Page 621: Rcl Override - Version A

    Crane operation 10.4 Operation of the rated capacity limiter 10.4.11 RCL override – version B This section applies only when the supplied lifting capacity tables contain an entry other than EN 13000 in the header (1), e.g. the entry ASME . à...

  • Page 622: Datalogger

    Crane operation 10.4 Operation of the rated capacity limiter 10.4.12 Datalogger You can export data from the CCS crane control system to a USB stick and display this on a PC using the CraneEvaluation program supplied. • Open the Data logger menu (1). Export data You require a USB Stick (USB 2.0 / FAT32 file system / approx.
  • Page 623 Crane operation 10.4 Operation of the rated capacity limiter You need the CraneEvaluation program in order to display the exported data. Display the data The installation program is located in the CraneEvaluation folder on the Owner's USB stick supplied. Import data •...
  • Page 624 Crane operation 10.4 Operation of the rated capacity limiter Displaying the graphic • Select the desired period (7) and desired graphic. 1 Crane use (offers the greatest variety of information) 2 Lifting duration per utilisation area 3 Number of lifts per day 4 Number of lifts per reeving 5 Number of lifts per utilisation area 6 Wind speed for each day...
  • Page 625 Crane operation 10.4 Operation of the rated capacity limiter Displaying tables • Select the symbol (1) – a table is displayed. 2 List with all lifts 3 List with all events 4 List with all actuated switches When the Crane use graphic is also open, an element is displayed and marked in the respective other window when clicked.
  • Page 626 Crane operation 10.4 Operation of the rated capacity limiter Blank page 10 - 72 3 302 633 en Operating Instructions GMK5250L...

  • Page 627: Crane Operation With Main Boom

    Crane operation 10.5 Crane operation with main boom 10.5 Crane operation with main boom 10.5.1 Checks during crane operation Horizontal During crane operation, the truck crane may tilt if the ground gives way due alignment to varying loads. Risk of accidents if the truck crane is not level! The RCL calculates the working radius from the length and angle of the main boom.
  • Page 628 Crane operation 10.5 Crane operation with main boom Checking Strong winds can result in the truck crane becoming overloaded. the wind speed • Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed. The display (1) shows the current wind speed.

  • Page 629: Main Hoist

    Crane operation 10.5 Crane operation with main boom 10.5.2 Main hoist You can reeve the hoist rope of the main hoist on the main boom or on the lattice extension. Risk of accidents from accidentally operating a hoist! Always switch off the hoist that is not in use! Never operate the hoist if the hook block is unreeled and the hoist rope is completely wound onto the drum.
  • Page 630 Crane operation 10.5 Crane operation with main boom Switching on After the ignition is switched on, all of the power units will be switched off the main hoist and the lamps in the corresponding buttons will light up only dimly. •...
  • Page 631 Crane operation 10.5 Crane operation with main boom Maximum The maximum permissible hoist rope speed is limited automatically permissible hoist depending on the degree of utilisation of the lifting capacity. The scale of the rope speed limitation is specified in the supplied lifting capacity table. à...
  • Page 632 Crane operation 10.5 Crane operation with main boom à You can switch on the high-speed mode for a higher speed; p. 10 - 113. Switching off the If you no longer require the main hoist, you should switch it off to avoid main hoist unintentional use.

  • Page 633: Auxiliary Hoist

    Crane operation 10.5 Crane operation with main boom 10.5.3 Auxiliary hoist Risk of accidents when operating the auxiliary hoist! Read and observe all of the safety instructions in the section Main hoist , p. 10 - 75 before operating the auxiliary hoist. All safety instructions for the operation of the main hoist also apply to the auxiliary hoist, along with the information in this section.
  • Page 634 Crane operation 10.5 Crane operation with main boom • Check whether the current reeving of the auxiliary hoist is displayed, à e.g. 6. Correct the reeving if necessary; p. 10 - 39. Lifting and You can adjust the sensitivity of the control levers to suit the operating à...
  • Page 635 Crane operation 10.5 Crane operation with main boom You can adjust the desired engine speed (idling speed) with button (1); à p. 9 - 7. à You can limit the maximum hoist speed; p. 10 - 123. à You can switch on the high-speed mode for a higher speed; p.

  • Page 636: Lifting Limit Switch And Lowering Limit Switch

    Crane operation 10.5 Crane operation with main boom 10.5.4 Lifting limit switch and lowering limit switch à Lifting limit switch To install/remove the lifting limit switch; p. 11 - 120. The lifting limit switch (1) prevents the hook block from being lifted up to the main boom head and damaging it.
  • Page 637 Crane operation 10.5 Crane operation with main boom Lifting limit switch override When overriding, the shutdown of the lifting limit switch is cancelled and the crane operation is no longer completely monitored. Risk of accidents if the lifting limit switch is overridden! You may override the lifting limit switch only if this is specified in the oper- ating instructions for carrying out maintenance or rigging work.
  • Page 638 Crane operation 10.5 Crane operation with main boom Lowering limit switch The lowering limit switch (1) prevents the hoist rope from being reeled completely off the drum. The lowering limit switch works only if the switch-off point is set correctly à...

  • Page 639: Derricking Gear

    Crane operation 10.5 Crane operation with main boom 10.5.5 Derricking gear You can raise and lower the main boom. Depending on the size of the load and the rigging mode, the RCL will switch off the lowering process of the boom as soon as leaving the working area specified in the Lifting capacity table .
  • Page 640 Crane operation 10.5 Crane operation with main boom Raising and You can adjust the sensitivity of the control levers to suit the operating con- à Setting the characteristic curves for the control levers , p. 10 - 126. lowering ditions; Risk of accident due to unexpected crane movements! If assigned more than one function, check that the Derricking control lever function is switched on before you move the control lever for derricking.
  • Page 641 Crane operation 10.5 Crane operation with main boom à You can switch on the high-speed mode for a higher speed; p. 10 - 113. Re-enable raising If the RCL has switched off the raising function due to an overload, you can function re-enable the raising function with button (1).
  • Page 642 Crane operation 10.5 Crane operation with main boom Lowering the The main boom can be set down by referring to the working curves within the working range specified in the lifting capacity tables . main boom to a horizontal position These additional pages supplement the information (1) in the lifting capacity tables supplied for the main boom intermediate lengths.

  • Page 643: Telescoping Mechanism

    Crane operation 10.5 Crane operation with main boom 10.5.6 Telescoping mechanism A telescoping process requires locking and unlocking processes in the main boom. You can telescope the main boom in different ways. – Manual telescoping For manual telescoping, you must initiate all locking and unlocking processes at the right time.
  • Page 644 Crane operation 10.5 Crane operation with main boom Overview This illustration shows the completely retracted main boom with the basic section (9) and the first three telescopic sections I to III (1) to (3). Each telescopic section is equipped with two locking pins (7) which are extended by spring force.
  • Page 645 Crane operation 10.5 Crane operation with main boom 1. Unlocking the telescoping cylinder The locking pins (5) retract – the telescoping cylinder is unlocked. 2. Moving and locking the telescoping cylinder The telescoping cylinder moves into the sec- tion to be telescoped, e.g. telescopic section III (3).
  • Page 646 Crane operation 10.5 Crane operation with main boom 4. Telescoping, locking and setting down a telescopic section The telescoping cylinder pushes the telescopic section to a locking point. The weight is taken off the mechanism (10). The locking pins (7) extend into the cutouts (4). The telescopic section is automatically set down.
  • Page 647 Crane operation 10.5 Crane operation with main boom The CCS display shows a sectional view of the main boom in the menus. Assignment for display The following elements are displayed: 0 Basic section 1 Telescopic section I 2 Telescopic section II 3 Telescopic section III 4 Locking pin on the telescopic section 5 Locking pins on the telescoping cylinder...
  • Page 648 Crane operation 10.5 Crane operation with main boom Fixed length, There are lifting capacity tables for main boom fixed lengths, main boom intermediate intermediate lengths and main boom telescoping lengths. length, telescop- The lengths are automatically detected by the RCL, and the corresponding lifting capacities according to the lifting capacity table are enabled and dis- ing length played automatically.
  • Page 649 Crane operation 10.5 Crane operation with main boom Telescoping The position of the telescopic sections, i.e. which telescopic section is extended to what extent, is referred to as telescoping. The CCS display shows main boom fixed lengths and main boom intermediate/telescoping lengths in different ways.
  • Page 650 Crane operation 10.5 Crane operation with main boom Checks before Checking the current telescope status starting work When the ignition is turned on, CCS registers the displayed telescoping sta- tus from the current status of the telescoping mechanism and the previ- ously saved locking and unlocking procedures.
  • Page 651 Crane operation 10.5 Crane operation with main boom Switching on After the ignition is switched on, all of the power units will be switched off the telescoping and the lamps in the corresponding buttons will light up only dimly. mechanism •...
  • Page 652 Crane operation 10.5 Crane operation with main boom Risk of damage to the hoist rope! The rope can become slack if the hook block touches the ground during retraction operations. Rope loops will form, which can cause the load to slip and damage the hoist rope.
  • Page 653 Crane operation 10.5 Crane operation with main boom With certain telescoping states, the RCL will switch telescoping off, e.g. when you leave the telescoping lengths or when the working range limit has à RCL shutdown , p. 10 - 58. been reached;...
  • Page 654 Crane operation 10.5 Crane operation with main boom Manual To telescope manually, you must initiate all locking and unlocking proc- telescoping esses. The locking and unlocking processes are carried out automatically. The following sections describe the operating procedures – Checking the initial position, à...
  • Page 655 Crane operation 10.5 Crane operation with main boom Current telescoping The display (1) shows how far the telescoping cylinder is extended, e.g. 98%. The display (2) shows the current main boom length. The display (3) shows the corresponding tele- scopic section, e.g. telescopic section 3 . Position of the telescoping cylinder The display (1) shows how far the telescoping cylinder is extended, e.g.
  • Page 656 Crane operation 10.5 Crane operation with main boom Position of the locking pins The current positions of the locking pins are: 1 On the telescopic section 2 On the telescoping cylinder The area (3) shows an enlarged cut-out. The current settings are shown in different colours.
  • Page 657 Crane operation 10.5 Crane operation with main boom Unlocking • Select the symbol (1). Confirm the selection – the locking pins (2) will retract. – Yellow: Intermediate position – Red: Unlocked Operating Instructions GMK5250L 3 302 633 en 10 - 103...
  • Page 658 Crane operation 10.5 Crane operation with main boom Extending/retract- ing the telescop- ing cylinder Prerequisites – Telescoping mechanism on – symbol (3) green – Telescopic section locked – symbol (1) green – Telescoping cylinder unlocked – symbol (2) Extending/retracting • Move the control lever in the corresponding telescoping direction: –...
  • Page 659 Crane operation 10.5 Crane operation with main boom Risk of damage to the boom system! If extending and retracting several times does not lead to the lock being released, you must not telescope any further against the stop. If removing the load does not cause the lock to be released, you must lock à...
  • Page 660 Crane operation 10.5 Crane operation with main boom Unlocking the tel- Unlocking a telescopic section is required for the telescopic section to be escopic section telescoped. The telescoping cylinder and the telescopic section cannot be unlocked simultaneously. Prerequisites – Telescoping mechanism on – symbol (3) green –...
  • Page 661 Crane operation 10.5 Crane operation with main boom Risk of damage to the boom system! If extending and retracting several times does not lead to the lock being released, you must not telescope any further against the stop. If removing the load does not cause unlocking, you must lock the telescopic à...
  • Page 662 Crane operation 10.5 Crane operation with main boom Locking the tele- Every telescopic section can be locked at the fixed lengths – fixed lengths; à scopic section p. 10 - 94. Prerequisites – Telescoping mechanism on – symbol (3) green –...
  • Page 663 Crane operation 10.5 Crane operation with main boom Before on-road Locking the telescopic section for on-road driving driving Once you have retracted the main boom for on-road driving, you must by all means lock the telescoping cylinder in telescopic section I , so that the axle loads are in accordance with the values in the Driving mode table;...
  • Page 664 Crane operation 10.5 Crane operation with main boom Telescoping with When telescoping with semi-automation, you enter the desired fixed semi-automaton lengths and then move the control lever in the required direction. Switching between the telescopic sections is carried out automatically by CCS. If the desired telescoping status is not a fixed length, you can first telescope to the next closest fixed length with the semi-automation and then tele- scope further to the desired length manually.
  • Page 665 Crane operation 10.5 Crane operation with main boom Confirm the entry • Select and confirm the symbol (1). Telescoping • Move the control lever for the displayed telescoping direction. 2 Extending 3 Retracting 4 Display in the case of return runs (without a telescopic section) End telescoping semi-automation The teleautomation will stop when the entered...
  • Page 666 Crane operation 10.5 Crane operation with main boom Telescoping with No additional telescoping menu needs to be opened for this type of tele- scoping operation. All displays are shown in the Monitoring RCL menu. Pre- pre-selection selection of the telescope status has already been performed when entering à...

  • Page 667: High-Speed Mode

    Crane operation 10.5 Crane operation with main boom 10.5.7 High-speed mode The slewing gear cannot be operated in high-speed mode. You can switch on the high-speed mode for a higher speed. Risk of accidents due to the suddenly accelerating movement! Reduce the engine speed before starting high-speed mode.
  • Page 668 Crane operation 10.5 Crane operation with main boom Hoists High-speed mode is always switched on and off simultaneously for the main hoist and the auxiliary hoist. Risk of accidents due to overloading! Make sure the lifted load is no more than 50% of the maximum load accord- ing to the Lifting capacity table (maximum degree of utilisation of 50%) before operating the hoists in high-speed mode.

  • Page 669: Slewing Gear

    Crane operation 10.5 Crane operation with main boom 10.5.8 Slewing gear Danger of overturning when slewing with a rigged counterweight! Always check before slewing whether slewing is permitted in the truck crane's current rigging mode (counterweight, outrigger span, working radius). à...
  • Page 670 Crane operation 10.5 Crane operation with main boom Slewing The following requirements must be fulfilled before slewing: à – The superstructure is unlocked; p. 10 - 15. à – Slewing is permissible with the current rigging mode; p. 11 - 93. –...
  • Page 671 Crane operation 10.5 Crane operation with main boom Maximum permit- The maximum permissible slewing speed is limited automatically depend- ted slewing speed ing on the working radius and degree of utilisation of the lifting capacity. The scale of the limitation is specified in the supplied lifting capacity table. à...
  • Page 672 Crane operation 10.5 Crane operation with main boom Braking the You may only brake the slewing movement with the slewing gear brake. slewing movement Risk of the main boom buckling! On no account switch the slewing gear off to brake it; only switch the slewing gear off when the superstructure has stopped rotating.
  • Page 673 Crane operation 10.5 Crane operation with main boom Slewing gear The slewing gear freewheel is required if the slewing gear needs to be freewheel slewed by means of external forces, e.g. when operating with two cranes. • Switch on the slewing gear. •...

  • Page 674: Possible Movement Combinations

    Crane operation 10.5 Crane operation with main boom 10.5.9 Possible movement combinations – The main hoist, telescoping mechanism, derricking gear and slewing gear can be operated in almost any combination simultaneously. Restrictions are specified for the respective power units. – The auxiliary power units – Superstructure lock, tilt crane cab, counter- weight lifting unit –...

  • Page 675: Settings And Displays For Crane Operation

    Crane operation 10.6 Settings and displays for crane operation 10.6 Settings and displays for crane operation This section only describes settings and displays needed during crane oper- ation. Operating elements that can be assigned to other procedures are described with the corresponding procedures. 10.6.1 Inclining the crane cab With the appropriate equipment, you can incline the crane cab to the rear in...

  • Page 676: Set Idling Speed

    Crane operation 10.6 Settings and displays for crane operation 10.6.2 Set idling speed à Set idling speed , p. 9 - 7. 10.6.3 Adjusting the wiper stroke interval of the windscreen wiper You can set a value between 3 and 30 seconds for the front and roof window wiper stroke interval.

  • Page 677: Limiting The Power Unit Speeds

    Crane operation 10.6 Settings and displays for crane operation 10.6.4 Limiting the power unit speeds You can enter what percentage of the maximum speed should be enabled for each power unit. • Open the Power unit speeds menu (1). The values below the symbols (1) to (6) indi- cate the currently set power unit speeds.

  • Page 678: Setting/Switching On Economy Mode

    Crane operation 10.6 Settings and displays for crane operation 10.6.5 Setting/switching on Economy mode If you do not move the control lever during crane operation then the engine speed is reduced in 2 steps. You can adjust the time interval between the steps.

  • Page 679: Switching Units Of Measure

    Crane operation 10.6 Settings and displays for crane operation 10.6.6 Switching units of measure You can display the crane control values in metric units or US units. • Open the Switch units menu (1). • Select and confirm the symbol: 1 To display metric units 2 To display US units The symbol (3) shows the respective confirmed...

  • Page 680: Setting The Characteristic Curves For The Control Levers

    Crane operation 10.6 Settings and displays for crane operation 10.6.7 Setting the characteristic curves for the control levers The control lever characteristic curve determines how high the power unit speed should be for a particular control lever movement. You can assign different control lever characteristic curves to the power units.

  • Page 681: Using The Slewable Spotlights

    Crane operation 10.6 Settings and displays for crane operation 10.6.8 Using the slewable spotlights With the relevant equipment, the slewable spotlights (1) are located on the main boom. They are controlled from the crane cab. Risk of damage to the slewable spotlights! Make allowances for the position of the slewable spotlights before setting down the main boom.
  • Page 682 Crane operation 10.6 Settings and displays for crane operation Manually swinging Swing upwards • Press the button (1) in at the top. Turn downwards • Press the button (1) in at the bottom. The direction of the spotlights will be adjusted until you let go of the button or they reach their end position.

  • Page 683: Override Torque Reduction

    Crane operation 10.6 Settings and displays for crane operation 10.6.9 Override torque reduction If the engine torque has been reduced then the symbol (2) is shown in the start menu. You can override the torque reduction function for a limited time while working with the crane.

  • Page 684: Displaying The Operating Hours

    Crane operation 10.6 Settings and displays for crane operation 10.6.10 Displaying the operating hours You can view the total operating hours for all power units in the Operating hours menu. You can also delete the recorded operating hours. The total operating hours cannot be deleted. •...

  • Page 685: Working Range Limiter

    Crane operation 10.7 Working range limiter 10.7 Working range limiter You can set and monitor three different limits in the working range limiter menus: – a maximum overall height, – a maximum working radius, – a maximum slewing angle, – a limited rope travel. The monitoring of the programmed limits can be switched on and off separately.

  • Page 686: Viewing Current Settings

    Crane operation 10.7 Working range limiter 10.7.1 Viewing current settings On the RCL The displays show monitoring and speed limitations that are switched on. display Working range limiter displays The corresponding symbol is shown when a monitoring system is switched on. 1 Hoist rope travel limitation monitoring 2 Overall height monitoring 3 Slewing angle monitoring...

  • Page 687: Opening The Working Range Limiter Menu

    Crane operation 10.7 Working range limiter The RCL shows the limited working range for the slewing angle and working In the CCS Start menu radius monitoring systems. Display examples for switched-on slewing angle and working radius monitoring systems. 1 Permissible working range according to the lifting capacity table –...
  • Page 688 Crane operation 10.7 Working range limiter The working range limiter values are displayed graphically and numerically. Limit values/current values for height The symbols show values for: 1 Current overall height 2 Permissible overall height Limit values/current values for working radius The symbols show values for 1 current working radius 2 permissible working radius...
  • Page 689 Crane operation 10.7 Working range limiter Limit values/current values for slewing angle The symbols show values for 1 current slewing angle A 2 permissible slewing angle A 3 current slewing angle B 4 permissible slewing angle B The following applies to the slewing angle display: 0 means that the superstructure is slewed to the rear.

  • Page 690: Entering Limit Values

    Crane operation 10.7 Working range limiter 10.7.3 Entering limit values This section describes how to enter unknown limit values by moving to the shutdown points. à Entering limit values manually , You can enter known limit values directly; p. 10 - 140. Risk of accidents due to limits set too low! When entering the limit values, bear in mind that, even after switching off the engine, movements can still occur that would bring the load into the...
  • Page 691 Crane operation 10.7 Working range limiter Working radius • Move the main boom head to just before the shutdown point without a load, e.g. up to 10.0 m – value (1). • Press the button (3) or (4) once. – The current value (1) will be accepted as the limit value (2).
  • Page 692 Crane operation 10.7 Working range limiter Entering the permissible slewing range You must enter the slewing angles A and B separately. Slewing angle A • Slew the main boom to the shutdown point from the right, e.g. value (1). • Press the button (5) or (6) once.
  • Page 693 Crane operation 10.7 Working range limiter Limiting lifting • Lift the load to the necessary height. Select the symbol (1). • Press the button (6) or (7) once. The current numerical value (5) is set at the symbol (2) as the upper limit value, symbol (1) confirms the entry.

  • Page 694: Entering Limit Values Manually

    Crane operation 10.7 Working range limiter 10.7.4 Entering limit values manually When entering the values: à Switching The monitoring must be switched off – symbol (1) is red; monitoring functions on/off , p. 10 - 142. Limit values The limit values for the overall height, the working radius, and the slewing angle are entered in the same way.
  • Page 695 Crane operation 10.7 Working range limiter – For slewing angles • Set the respective limit value and confirm with button (3) or (4). The value is adopted. – The symbol (1) for the slewing angle A – symbol is red, –...

  • Page 696: Switching Monitoring Functions On/Off

    Crane operation 10.7 Working range limiter 10.7.5 Switching monitoring functions on/off After turning on the ignition, all monitoring functions that were on before the ignition was switched off are switched on. When monitoring is switched on, the movement towards the shutdown limit is continually reduced until reaching a standstill.

  • Page 697: Shutdown By Working Range Limiter

    Crane operation 10.7 Working range limiter 10.7.6 Shutdown by working range limiter If a limit value is reached, RCL shutdown will occur. All movements that would go closer to the limit value will be disabled. Shutdown will remain active even if you switch off the monitoring function. The RCL display also shows an information symbol.
  • Page 698 Crane operation 10.7 Working range limiter Blank page 10 - 144 3 302 633 en Operating Instructions GMK5250L...

  • Page 699: Work Break

    Crane operation 10.8 Work break 10.8 Work break 10.8.1 In case of short work breaks Risk of accidents due to suspended loads! Never switch off the engine whilst a load is suspended. You must have the control levers at hand in order to intervene at any time. Always set down the load before you leave the crane cab.

  • Page 700: In Case Of Work Breaks Of More Than 8 Hours

    Crane operation 10.8 Work break 10.8.2 In case of work breaks of more than 8 hours • Retract all telescopic sections. • Lower the main boom. • Switch off the slewing gear. – The lamp in the button (1) must be dimly lit. –...

  • Page 701: Heating And Air-Conditioning System

    Crane operation 10.9 Heating and air-conditioning system 10.9 Heating and air-conditioning system • Do not cover the grille (1). Air is sucked in through the grille. 10.9.1 Standard heating system • Switching on Switch on the ignition or start the engine. The batteries will run down if you operate the heater with the engine switched off.
  • Page 702 Crane operation 10.9 Heating and air-conditioning system Setting the air You can direct the air to flow out of various air vents. distribution • Select the corresponding symbol (1) for the desired air vents. A Top only B Top and bottom C Bottom only Danger of overheating! Never close all air vents when the heating is switched on.

  • Page 703: Air-Conditioning System

    Crane operation 10.9 Heating and air-conditioning system 10.9.2 Air-conditioning system You can use the air-conditioning system to cool and dry the air in the crane cab. Information Do not cool the air in the crane cab too much. The difference between the outside temperature and the inside temperature should be at the most 10 °C to 14 °C (50 °F to 57.2 °F).
  • Page 704 Crane operation 10.9 Heating and air-conditioning system Cooling, The illustration shows only a sample setting. Always adjust the setting to automatic the current conditions. • Select and confirm the symbol (1) – Symbol red. • Set the desired temperature – Symbol (2). •...

  • Page 705: Auxiliary Heater

    Crane operation 10.9 Heating and air-conditioning system 10.9.3 Auxiliary heater You can use the auxiliary air heater to preheat the crane cab. The batteries will be drained if you operate the auxiliary heater with the engine switched off. You must recharge the batteries at shorter intervals if you use the auxiliary heater frequently! Switching on You can set an automatic start time and duration for the heating, over...
  • Page 706 Crane operation 10.9 Heating and air-conditioning system Setting the temperature • Select the symbol (1). • Set the desired temperature – Symbol (2). • Change and confirm the respective values using the controls (3) or (4). Setting the heating start/ heating duration •...
  • Page 707 Crane operation 10.9 Heating and air-conditioning system Switching heating start on/off Switching on • Select a storage location (e.g. #1) – symbol (1) red. You can also selected other storage locations. The auxiliary heating now starts at the times stored in the corresponding column. Switching off •...

  • Page 708: Cranestar System

    Crane operation 10.10 CraneSTAR system 10.10 CraneSTAR system 10.10.1 Overview Your truck crane is equipped with the CraneSTAR system. The CraneSTAR system is used to transmit crane data via mobile phone, thus allowing remote diagnostics and localisation of the truck crane. The CraneSTAR system works automatically, no controls must be operated.

  • Page 709: Rigging Work

    Rigging work 11.1 Rigging work checklists for crane operation with the main boom Rigging work If the truck crane on the site has already been rigged, proceed according to the CHECKLIST: Checks before operating the crane , p. 10 - 1. 11.1 Rigging work checklists for crane operation with the main boom...
  • Page 710 Rigging work 11.1 Rigging work checklists for crane operation with the main boom 4. Check whether the ground will support the maximum occurring outrig- à Determining the required load-bearing area , p. 11 - 9. ger pressures; 5. Switch off (lock) the suspension. à...
  • Page 711 Rigging work 11.1 Rigging work checklists for crane operation with the main boom 10. Fold out all ladders and extend all stair treads; à Ladders , p. 4 - 5, à Step at the crane cab , p. 11 - 141. 11.
  • Page 712 Rigging work 11.1 Rigging work checklists for crane operation with the main boom à 15. Install the lifting limit switch; p. 11 - 120. 16. Install anemometer, air traffic control light and camera on main boom; à Anemometer and air traffic control light , p. 11 - 126, à...

  • Page 713: Checklist: Unrigging

    Rigging work 11.1 Rigging work checklists for crane operation with the main boom 11.1.2 CHECKLIST: Unrigging This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there! à...
  • Page 714 Rigging work 11.1 Rigging work checklists for crane operation with the main boom 5. Depending on transport: à – Attach the hook block to the bumper; p. 11 - 96 or – Set down the hook block and unreeve the hoist rope; à...
  • Page 715 Rigging work 11.1 Rigging work checklists for crane operation with the main boom 11. Remove camera on main boom; à Camera on main boom , p. 11 - 137. à Using the slewable spotlights , Lower the slewable spotlights; p. 10 - 127. à...
  • Page 716 Rigging work 11.1 Rigging work checklists for crane operation with the main boom Blank page 11 - 8 3 302 633 en Operating Instructions GMK5250L...

  • Page 717: Selecting The Suitable Site

    Rigging work 11.2 Selecting the suitable site 11.2 Selecting the suitable site Choose the position of your truck crane at the site with care. Observe the following aspects: – Check that the ground has sufficient load bearing capacity. You may need à...
  • Page 718 Rigging work 11.2 Selecting the suitable site Load bearing capacity of the ground • Find the load bearing capacity of the ground using the table. Load bearing APPROXIMATE VALUES FOR THE LOAD BEARING capacity t/m CAPACITY OF THE GROUND (lbs/ft Backfilled, not artificially compacted ground: 0 to 10 (0 to 2,050)
  • Page 719 Rigging work 11.2 Selecting the suitable site Load-bearing area • Now calculate the required load-bearing area. à • Check that the surface of the outrigger pad ( p. 1 - 17) is larger than the calculated ground bearing area. If the surface of the outrigger pad is smaller, you will need to enlarge the load-bearing area.

  • Page 720: Safe Distance From Slopes And Pits

    Rigging work 11.2 Selecting the suitable site 11.2.2 Safe distance from slopes and pits Erect the crane at a safe distance from slopes and pits. The distance also depends on the type of ground if the slopes and pits are not supported. As a rule of thumb: If you are working on non-cohesive or filled-in ground, the safety distance (a) must be twice...

  • Page 721: Earthing The Truck Crane

    Rigging work 11.2 Selecting the suitable site 11.2.3 Earthing the truck crane The truck crane may become charged with static electricity. This may occur especially when using outrigger pads made of plastic or when the outrigger pads are packed with insulating material (e.g. wooden planks). Risk of accidents due to electric shock! Earth the truck crane before you start to work with it –...

  • Page 722: Safe Distance From Overhead Power Lines

    Rigging work 11.2 Selecting the suitable site 11.2.4 Safe distance from overhead power lines Always observe the regulations in the country in which you are working when working in the vicinity of overhead power lines. Risk of accidents due to electric shock! The truck crane is not insulated.
  • Page 723 Rigging work 11.2 Selecting the suitable site For example, according to DIN VDE 0105 Voltage Safe distance (A) up to 1,000 V 1 m (3.3 ft) over 1,000 V to 110,000 V 3 m (9.8 ft) over 110,000 V to 220,000 V 4 m (13.1 ft) over 220,000 V to 380,000 V 5 m (16.4 ft)
  • Page 724 Rigging work 11.2 Selecting the suitable site Blank page 11 - 16 3 302 633 en Operating Instructions GMK5250L...

  • Page 725: Rigging Work After Driving With A Dolly

    Rigging work 11.3 Rigging work after driving with a dolly 11.3 Rigging work after driving with a dolly If the main boom is resting on a dolly whilst the truck crane is being driven, you must perform the following before working with the crane: à...

  • Page 726: Switching Off The Slewing Gear Freewheel

    Rigging work 11.3 Rigging work after driving with a dolly 11.3.2 Switching off the slewing gear freewheel If the slewing gear freewheel is switched on, switch it off prior to working with the crane. Risk of accidents with the slewing gear freewheel switched on! Switch off the slewing gear freewheel before working with the crane.

  • Page 727: Switching Off Boom Pre-Tensioning

    Rigging work 11.3 Rigging work after driving with a dolly 11.3.3 Switching off boom pre-tensioning You must switch off the boom pre-tensioning before you raise the main boom off the dolly. To switch off boom pre-tensioning, you must bring the valves I to IV into the required positions, which will empty the pressure accumulator.
  • Page 728 Rigging work 11.3 Rigging work after driving with a dolly Blank page 11 - 20 3 302 633 en Operating Instructions GMK5250L...

  • Page 729: Connecting/Disconnecting The Hand-Held Control

    Rigging work 11.4 Connecting/disconnecting the hand-held control 11.4 Connecting/disconnecting the hand-held control Functionality of the sockets Socket Released operations – Emergency operation with hand-held control – Rigging the auxiliary hoist – Emergency operation with hand-held control – Engine and supports Switch off the engine.
  • Page 730 Rigging work 11.4 Connecting/disconnecting the hand-held control Connecting the hand-held control • Open the cap (2) and pull the bridging plug (3) out of the socket (1). • Insert the plug (4) into the socket (1) and secure it with the cap (2). •...

  • Page 731: Starting The Engine For Driving For Rigging Work

    Rigging work 11.5 Starting the engine for driving for rigging work 11.5 Starting the engine for driving for rigging work The engine for driving must be running for rigging work, e.g., to move the outriggers. You can start the engine for driving: –...
  • Page 732 Rigging work 11.5 Starting the engine for driving for rigging work Start the engine All activities and checks required to start the engine must be carried out à before starting the engine; p. 4 - 1. • Wait until the lamps (1) and (2) illuminate. If the lamp (2) does not illuminate or flash after about 20 seconds, there is a à...
  • Page 733 Rigging work 11.5 Starting the engine for driving for rigging work 11.5.2 Starting/switching off the engine from the outrigger control units Prerequisites The following requirements must be met before you can start the engine for driving from the outrigger control units: –...
  • Page 734 Rigging work 11.5 Starting the engine for driving for rigging work Blank page 11 - 26 3 302 633 en Operating Instructions GMK5250L...

  • Page 735: Slewing Range - Only With The Standard Slewing Range Type

    Rigging work 11.6 Slewing range – only with the Standard slewing range type 11.6 Slewing range – only with the Standard slewing range type The information in this section applies only to the Standard slewing range type. If you wish to operate the truck crane using the MAXbase slewing à...

  • Page 736: Enabled Outrigger Spans

    Rigging work 11.6 Slewing range – only with the Standard slewing range type 11.6.2 Enabled outrigger spans Risk of overturning when slewing the superstructure! With some outrigger spans, slewing is only permissible with certain à Slewing with the counterweight combinations and boom positions; rigged counterweight , p.

  • Page 737: Outriggers - Overview - Maxbase Slewing Range Type

    Rigging work 11.7 Outriggers – Overview – MAXbase slewing range type 11.7 Outriggers – Overview – MAXbase slewing range type The information in this section applies to the MAXbase slewing range type. If you wish to operate the truck crane using the Standard slewing range type; à...
  • Page 738 Rigging work 11.7 Outriggers – Overview – MAXbase slewing range type Representation of the outrigger spans – Outrigger length The outrigger length ( I ) has a fixed value of 8.950 m (29.4 ft) and never changes. – Outrigger width All possible outrigger spans (1) to (5) are always shown for all outrigger beams.

  • Page 739: Representation In The Lifting Capacity Tables

    Rigging work 11.7 Outriggers – Overview – MAXbase slewing range type 11.7.2 Representation in the lifting capacity tables The outrigger span is always specified in this form Outrigger length xxxx – outrigger width yyyyy – The value xxxx is always 8.950 m (29.4 ft). –...

  • Page 740: Enabled Outrigger Spans

    Rigging work 11.7 Outriggers – Overview – MAXbase slewing range type Three / One The outrigger width is the same for three out- rigger beams and one outrigger beam is fully retracted. The overall width is entered once and an indi- vidual width is entered once.
  • Page 741 Rigging work 11.7 Outriggers – Overview – MAXbase slewing range type Right / Left – Right greater than left The outrigger width is the same at the left and the same at the right. The table shows the permissible combinations. FR / RR FL / RL 3.900 m (12.8 ft)
  • Page 742 Rigging work 11.7 Outriggers – Overview – MAXbase slewing range type Front / rear – Front greater than rear The front outrigger beams are extended fur- ther than the rear outrigger beams. The table shows the permissible combinations. FR / FL RR / RL 3.900 m (12.8 ft) 3.427 m (11.2 ft)
  • Page 743 Rigging work 11.7 Outriggers – Overview – MAXbase slewing range type Three / One – One outrigger beam retracted – left Three outrigger beams are extended the same distance and one outrigger beam at the left side is retracted. The table shows the permis- sible combinations.
  • Page 744 Rigging work 11.7 Outriggers – Overview – MAXbase slewing range type Blank page 11 - 36 3 302 633 en Operating Instructions GMK5250L...

  • Page 745: Outrigger Operation

    Rigging work 11.8 Outrigger operation 11.8 Outrigger operation Risk of crushing by extending outrigger beams! You may only activate the outriggers if you yourself or a banksman with whom you are in visual contact have an unobstructed view of their movements.
  • Page 746 Rigging work 11.8 Outrigger operation 5. Enlarge the ground bearing area if necessary; à Determining the required load-bearing area , p. 11 - 9, à Enlarging the load-bearing area , p. 11 - 52. 6. Extend the supporting cylinders until none of the wheels is touching the ground;...

  • Page 747: Checklist: Retracting The Outriggers

    Rigging work 11.8 Outrigger operation 11.8.2 CHECKLIST: Retracting the outriggers This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there! à 1. Retract the outrigger cylinders as far as possible; p.
  • Page 748 Rigging work 11.8 Outrigger operation 6. Switch off the engine; à – After operating it from the control units; p. 4 - 21. – After operating it from the crane cab or using the hand-held control; à p. 9 - 9. 7.

  • Page 749: Preparing The Truck Crane

    Rigging work 11.8 Outrigger operation 11.8.3 Preparing the truck crane In the driver's cab Levelling the truck crane • Align the truck crane horizontally with the level adjustment system; à Operating the level adjustment system , p. 5 - 52. Locking the suspension à...

  • Page 750: Setting The Spans

    Rigging work 11.8 Outrigger operation 11.8.4 Setting the spans Danger of overturning if the outrigger beams are not correctly extended! Extend the outrigger beams only as far as the permissible spans. Always extend all outriggers to the outrigger spans specified in the lifting capacity table for the planned application.
  • Page 751 Rigging work 11.8 Outrigger operation Total width 6.854 m (22.4 ft) Individual width 3.427 m (11.2 ft) (A) – Prerequisites Pins (1) and (2) must be pulled out (B) – Setting and securing • Extend the outrigger beam up to the marking (3).
  • Page 752 Rigging work 11.8 Outrigger operation Total width 4.310 m (14.2 ft) Individual width 2.155 m (7.1 ft) (A) – Prerequisites – Pin (1) must be removed – Pin (2) must be inserted (B) – Setting and securing • Extend the outrigger beam up to the marking (3).

  • Page 753: Extending/Retracting Outrigger Beams

    Rigging work 11.8 Outrigger operation 11.8.5 Extending/retracting outrigger beams Risk of accidents if outrigger beams cannot be seen! Cordon off the area where you intend to extend and retract the outrigger beams. Nobody is allowed to be in this area. Observe the moving outrigger beams or have them observed by a banks- man who is in visual contact with you.
  • Page 754 Rigging work 11.8 Outrigger operation If the hand-held control is connected, the Outrigger operating units are From the control units inactive. Start the engine • Remove the hand-held control if necessary, and start the engine from the à driver's cab; p.
  • Page 755 Rigging work 11.8 Outrigger operation With the hand- The hand-held control must be connected to the carrier. held control • Connect the hand-held control to the required socket (1) or (2). 1 For the right-hand outrigger beam 2 For the left-hand outrigger beam à...
  • Page 756 Rigging work 11.8 Outrigger operation Pre-selecting outriggers You can only pre-select outriggers on the side to which the hand-held control is connected. • Press the button for the required outrigger once. 1 Front left 2 Front right 3 Rear left 4 Rear right 1 + 3 Both on left 2 + 4 Both on right...
  • Page 757 Rigging work 11.8 Outrigger operation The operating elements are in the Outriggers submenu. From the crane cab Start the engine à • Start the engine from the crane cab; p. 9 - 5. à • Switch off the slewing gear; p.
  • Page 758 Rigging work 11.8 Outrigger operation Retract • Press the button for the desired outrigger beam. 1 Front left 2 Front right 3 Rear left 4 Rear right • Press the button (5) in at the bottom – the selected outrigger beam retracts. 11 - 50 3 302 633 en Operating Instructions GMK5250L...

  • Page 759: Moving The Outrigger Pads Into Working/Driving Position

    Rigging work 11.8 Outrigger operation 11.8.6 Moving the outrigger pads into working/driving position The illustrations show one outrigger pad. The pulling direction of the other outrigger pads may differ from this. Moving them into working position • (A) – Pull out the pin (1). •...

  • Page 760: Enlarging The Load-Bearing Area

    Rigging work 11.8 Outrigger operation 11.8.7 Enlarging the load-bearing area If the surface of the outrigger pads is too small, you must enlarge the à Determining the ground bearing area by packing the outrigger pads; required load-bearing area , p. 11 - 9. For packing, use only suitable materials that will withstand the outrigger pressure, e.g.

  • Page 761: Extending/Retracting Supporting Cylinders

    Rigging work 11.8 Outrigger operation 11.8.8 Extending/retracting supporting cylinders Risk of overturning if the load bearing capacity of the ground is too low! Enlarge the load-bearing area if the ground cannot withstand the resulting outrigger pressure. This prevents the ground under the outrigger pad giving way and causing the truck crane to tilt and overturn.
  • Page 762 Rigging work 11.8 Outrigger operation If the hand-held control is connected, the Outrigger operating units are From the control units inactive. Start the engine • Disconnect the hand-held control, if necessary, and start the engine either: à – From the driver's cab; p.
  • Page 763 Rigging work 11.8 Outrigger operation à • With the hand- Connect the hand-held control to any socket on the carrier; p. 11 - 22. held control Start the engine à • Press the button (1) – the engine starts; p. 9 - 8. Pre-select high-speed mode/normal speed •...
  • Page 764 Rigging work 11.8 Outrigger operation Extending/retracting supporting cylinders • Observe the safety instructions for operating the supporting cylinders; à p. 11 - 53. • Press the button combination for the desired movement: 1 Extend 2 Retract The pre-selected supporting cylinders move until you let go of the respec- tive button or until the respective end position has been reached.
  • Page 765 Rigging work 11.8 Outrigger operation Extend • Press the button for the desired outrigger cylinder. 1 Front left 2 Front right 3 Rear left 4 Rear right • Press the button (5) in at the top – the selected outrigger beam extends. Retract •...

  • Page 766: Levelling The Truck Crane On Outriggers

    Rigging work 11.8 Outrigger operation 11.8.9 Levelling the truck crane on outriggers You must level the truck crane before crane operation and possibly correct its horizontal alignment during crane operation. Inclination After switching on the ignition, various inclination indicators display the indicators current alignment.
  • Page 767 Rigging work 11.8 Outrigger operation – Manual control/ CCS display The assignment to the carrier is given by the directional indicator (1). In this example, the carrier would be stand- ing higher to the rear on the right hand side. –...
  • Page 768 Rigging work 11.8 Outrigger operation Risk of overloading the main boom! Always slew the superstructure to the 0° or 180° position and set down the load before levelling the truck crane. In other positions, the deformation of the carrier will distort the indicated inclination and the truck crane will be at an angle.
  • Page 769 Rigging work 11.8 Outrigger operation Automatic During the automatic alignment procedure, the supporting cylinders alignment are extended only to prevent any wheels touching the ground after the alignment. à • Check that the prerequisites are met; p. 11 - 59. •...
  • Page 770 Rigging work 11.8 Outrigger operation Automatic procedure 1. All the supporting cylinders are extended one after the other until the outrigger pads touch the ground. 2. All the supporting cylinders are extended simultaneously so that none of the wheels is touching the ground any more. 3.

  • Page 771: Operating The Axle Raising System

    Rigging work 11.8 Outrigger operation 11.8.10 Operating the axle raising system The axle raising system has two functions. – Lifting/lowering wheels When the truck crane is supported on outriggers, you can raise the wheels (e.g. levelling horizontally) or lower the wheels (e.g. for driving with a rigged mobile crane).
  • Page 772 Rigging work 11.8 Outrigger operation • Press the button for the desired movement. Lifting/lowering wheels 1 Lifting wheels 2 Lowering wheels Aligning the truck crane 1 Lowering the truck crane 2 Lifting the truck crane 11 - 64 3 302 633 en Operating Instructions GMK5250L...

  • Page 773: Outrigger Pressure Display

    Rigging work 11.8 Outrigger operation 11.8.11 Outrigger pressure display Especially with asymmetrical outrigger spans, the outrigger pressure dis- plays do not provide useful information on correct alignment. Horizontal alignment is the decisive factor for correctly supporting the truck crane; à p.
  • Page 774 Rigging work 11.8 Outrigger operation On the outrigger control units The assignment of the displays to the carrier corresponds to the top view. 1 Display for the supporting cylinder 1.1 2 Display for the supporting cylinder 2.1 3 Display for the supporting cylinder 3.1 4 Display for the supporting cylinder 4.1 11 - 66 3 302 633 en...

  • Page 775: Rigging/Unrigging The Counterweight

    Rigging work 11.9 Rigging/unrigging the counterweight 11.9 Rigging/unrigging the counterweight Depending on the version, the GMK5250L can be rigged with counterweight mass of 7 t (15,432 lbs) to 80.1 t . 11.9.1 Information on rigging Rigging the counterweight is a challenging task. Only experienced person- nel who are familiar with the valid accident prevention regulations are authorised to sling counterweight sections and instruct the crane operator.
  • Page 776 Rigging work 11.9 Rigging/unrigging the counterweight As the crane operator • Use only the Raise/lower hoist or Raise/lower derricking gear movements for setting down the counterweight. Execute the movement as slowly as possible. Notify the rigging personnel if the superstructure need to be slewed for positioning the counterweight.
  • Page 777 Rigging work 11.9 Rigging/unrigging the counterweight 11.9.2 Counterweight sections The counterweight combinations can be comprised of: Counterweight 50 t (110,231 lbs) – One 7 t base plate (1) – Two 4.75 t counterweight sections (2) – One 4.5 t counterweight section (3) –...
  • Page 778 Rigging work 11.9 Rigging/unrigging the counterweight Blank page 11 - 70 3 302 633 en Operating Instructions GMK5250L...

  • Page 779: Identification

    Rigging work 11.9 Rigging/unrigging the counterweight 11.9.3 Identification The truck crane and its corresponding counterweight sections are labelled with the same serial number. Danger if counterweight sections are interchanged! Operate the truck crane only with the counterweight sections that belong to it.

  • Page 780: Slinging Points On The Counterweight Sections

    Rigging work 11.9 Rigging/unrigging the counterweight 11.9.4 Slinging points on the counterweight sections Risk of accidents if used improperly! Attach the various counterweight sections only to the intended slinging points and use lifting gear of sufficient lifting capacity. Only the slinging points of the base plate are designed for lifting specific counterweight combinations.
  • Page 781 Rigging work 11.9 Rigging/unrigging the counterweight Blocks • Sling the blocks at the slinging points (1). Operating Instructions GMK5250L 3 302 633 en 11 - 73...

  • Page 782: Checklist: Rigging The Counterweight

    Rigging work 11.9 Rigging/unrigging the counterweight 11.9.5 CHECKLIST: Rigging the counterweight This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there! Danger of overturning when slewing with a rigged counterweight! Always check before slewing whether slewing is permitted in the truck crane's current rigging mode (counterweight, outrigger span, working radius).

  • Page 783: Checklist: Unrigging The Counterweight

    Rigging work 11.9 Rigging/unrigging the counterweight 6. Enter the current rigging mode with the new rigged counterweight à combination at the RCL display; p. 10 - 32. 7. Only switch on the slewing gear if slewing is permissible for the current à...

  • Page 784: Assembling Counterweight Versions

    Rigging work 11.9 Rigging/unrigging the counterweight 4. – Open the Counterweight submenu; à – Correct the rigging mode, if necessary; p. 11 - 86, – Use the automatic system to lower the counterweight on to the coun- à terweight platform; p.
  • Page 785 Rigging work 11.9 Rigging/unrigging the counterweight Risk of accidents due to falling counterweight sections! Only attach the counterweight sections to the appropriate slinging points and use lifting gear of sufficient load bearing capacity. The counterweight sections should be lifted only one at a time. The slinging points are not designed for hoisting stacked counterweight sections.
  • Page 786 Rigging work 11.9 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all coun- terweight combinations that can be rigged. • The tables specify which counterweight sections are needed for the respective counterweight combination. à • Slinging points on Lift the counterweight sections onto the base plate;...
  • Page 787 Rigging work 11.9 Rigging/unrigging the counterweight Counterweight combination in t (lbs) Counterweight 16.5 21.0 26.0 30.5 sections (15,432) (36,376) (46,297) (57,320) (67,241) 5.0 t blocks – – – – – – 10.0 t blocks – – – – – – 10.0 t section –...
  • Page 788 Rigging work 11.9 Rigging/unrigging the counterweight The following counterweight combinations can be combined on the counterweight platform. Risk of accident due to an incorrect counterweight mass! Only combine the counterweights in such a manner that the counterweight mass corresponds to the specifications in this section and in the lifting capacity table .
  • Page 789 Rigging work 11.9 Rigging/unrigging the counterweight 21 t (46,297 lbs) – 7 t base plate – Two 4.75 t sections – One 4.5 t section 26 t (57,320 lbs) – 7 t base plate – Two 4.75 t sections – One 9.5 t section 30.5 t (67,241 lbs) –...
  • Page 790 Rigging work 11.9 Rigging/unrigging the counterweight 35.5 t (78,264 lbs) – 7 t base plate – Two 4.75 t sections – Two 9.5 t sections 40 t (88,185 lbs) – 7 t base plate – Two 4.75 t sections – One 4.5 t section –...
  • Page 791 Rigging work 11.9 Rigging/unrigging the counterweight 50 t (110,231 lbs) – 7 t base plate – Two 4.75 t sections – One 4.5 t section – Two 9.5 t sections – One 10 t section Risk of overturning if counterweight rigging sequence is incorrect! When installing, always attach both 10-t counterweight blocks before you attach a 5-t counterweight block and, during removal, always remove both 5-t counterweight blocks before you remove a 10-t counterweight block.
  • Page 792 Rigging work 11.9 Rigging/unrigging the counterweight 80 t – 7 t base plate – Two 4.75 t sections – One 4.5 t section – Two 9.5 t sections – One 10 t section – Two 10 t blocks – Two 5 t blocks 11 - 84 3 302 633 en Operating Instructions GMK5250L...

  • Page 793: Counterweight Hoist Unit

    To operate the counterweight hoist unit, you must open the Counterweight Counterweight menu menu. • Open the Counterweight menu (1). The Counterweight menu opens. If an error symbol (1) s displayed during subsequent operation, then contact Manitowoc Crane Care Operating Instructions GMK5250L 3 302 633 en 11 - 85...
  • Page 794 Rigging work 11.9 Rigging/unrigging the counterweight Extending/ This section describes how to operate the lifting cylinders manually, retracting the – for correcting the displayed rigging mode and lifting cylinders – for pre-charging the counterweight afterwards. Risk of damage to the counterweight! With the override switch actuated, the functions are always enabled.
  • Page 795 Rigging work 11.9 Rigging/unrigging the counterweight Pre-tensioning When the symbol (3) is red, you must pre-tension the counterweight. • Select and confirm the symbol (1) until the symbol (2) becomes green. Automatic mode While the automatic mode is being executed, you can always à...
  • Page 796 Rigging work 11.9 Rigging/unrigging the counterweight Switch on automatic mode • Select and confirm the symbol (3). Execute the automatic mode. • Move the slewing control lever in the dis- played direction (1) or (2) – the automatic mode starts. –...
  • Page 797 Rigging work 11.9 Rigging/unrigging the counterweight Automatic mode While the automatic mode is being executed, you can always à unrigging Cancel automatic mode , p. 11 - 90. – Cancel the automatic mode; – Cancel the automatic mode by letting go of the control lever. After moving the lever in the displayed direction once more, the automatic mode is con- tinued.
  • Page 798 Rigging work 11.9 Rigging/unrigging the counterweight • Move the slewing control lever in the dis- played direction (1) or (2) – the automatic mode continues. – The superstructure turns into position (C). – The lifting cylinders retract (D). • Release the control lever. Cancel automatic You can cancel the automatic mode any time.

  • Page 799: Setting Down Counterweight For Driving The Truck Crane

    Rigging work 11.9 Rigging/unrigging the counterweight 11.9.9 Setting down counterweight for driving the truck crane For driving with axle loads of at the most 12 t (26,500 lbs) the counterweight à Driving modes , p. 6 - 1. must be completely unrigged; If the locally applicable regulations in the country of use allow driving with axle loads greater than 12 t (26,500 lbs) then up to 21.2 t (46,738 lbs) of coun- terweight can be transported on the truck crane.
  • Page 800 Rigging work 11.9 Rigging/unrigging the counterweight Observe the following points to avoid damage to the derricking cylinder. If a lattice extension is folded at the side: At most, set down – the 7.0 t base plate (1), – one 4.75 t section (2), –...

  • Page 801: Slewing With The Rigged Counterweight

    Rigging work 11.9 Rigging/unrigging the counterweight 11.9.10 Slewing with the rigged counterweight Slewing with a rigged counterweight is only permissible when: – The necessary outrigger span is rigged, – The current rigging mode is shown on the RCL display and –...
  • Page 802 Rigging work 11.9 Rigging/unrigging the counterweight Blank page 11 - 94 3 302 633 en Operating Instructions GMK5250L...

  • Page 803: Rigging Work On The Main Boom

    Rigging work 11.10 Rigging work on the main boom 11.10 Rigging work on the main boom 11.10.1 Hook block on the bumper Picking up the Depending on the driving mode, you must pick up the hook block from the à Driving modes , p.
  • Page 804 Rigging work 11.10 Rigging work on the main boom Attaching the Depending on the driving mode, you can attach the hook block to the front à Driving modes , p. 6 - 1. hook block bumper; Risk of accidents if the view is obstructed! The reeved rope lines obstruct the view of the runway.

  • Page 805: Hook Block In The Compartment

    Rigging work 11.10 Rigging work on the main boom 11.10.2 Hook block in the compartment The hook block or separable hook block, each with 3 or 5 sheaves, can be stored in the compartment for driving. Risk of overturning while slewing! Always check before slewing whether slewing is permitted in the truck crane's current rigging mode.
  • Page 806 Rigging work 11.10 Rigging work on the main boom Setting down the hook block • Slacken the hoist rope until the hook block (1) rests on the end stop (2). – Hook block: • Unreeve the hoist rope from the hook à...

  • Page 807: Hook Block On A Separate Vehicle

    Rigging work 11.10 Rigging work on the main boom 11.10.3 Hook block on a separate vehicle Risk of overturning while slewing! Always check before slewing whether slewing is permitted in the truck crane's current rigging mode. Correct the rigging mode if necessary; à...
  • Page 808 Rigging work 11.10 Rigging work on the main boom Picking up the Depending on the driving mode, the hook block can be placed on a separate à Driving modes , p. 6 - 1. hook block vehicle; • If the respective setting has been made in the RCL, slew the superstructure and lower the main boom until the boom head is directly above the hook block (1).
  • Page 809 Rigging work 11.10 Rigging work on the main boom • Detach the lifting limit switch weight (2) à from the hoist rope; p. 11 - 123. à • Unreeve the hoist rope; p. 11 - 111. • Secure the hook block (1) for transport. •...

  • Page 810: Hook Block, Separable

    Rigging work 11.10 Rigging work on the main boom 11.10.4 Hook block, separable The hook block can be separated for on-road driving. The block hook remains reeved and can be attached to the bumper. The hook can be transported separately, e.g. on a separate vehicle. Rigging for on-road driving •...
  • Page 811 Rigging work 11.10 Rigging work on the main boom Rigging for crane operation • Slacken the hoist rope and raise the main boom simultaneously. • Raise the main boom until the boom head is in a vertical position above the block hook (1).

  • Page 812: Reeving And Unreeving The Hoist Rope

    Rigging work 11.10 Rigging work on the main boom 11.10.5 Reeving and unreeving the hoist rope You must reeve a certain number of rope lines, depending on the required load bearing capacity. Four reeved rope lines correspond, for example, to à...
  • Page 813 Rigging work 11.10 Rigging work on the main boom Positioning • Insert the holder (3) and slide it onto the hoist rope (4) as far as it will go. • Fasten the fork (1) using the pin (2). • Secure the pin using the linchpin. Version B Removing •...
  • Page 814 Rigging work 11.10 Rigging work on the main boom Positioning • Insert the padlock (5) and slide it onto the hoist rope as far as it will go (6). • Fasten the bracket (2) to the padlock (5) using the pin (1). •...
  • Page 815 Rigging work 11.10 Rigging work on the main boom Reeving the Depending on the version, you can use the rigging aid for fitting the hoist à hoist rope rope if necessary; p. 6 - 69. Danger due to slack rope! Only use hook blocks and sling gear of the minimum weight prescribed in the Lifting capacity table depending on the reeving and boom length.
  • Page 816 Rigging work 11.10 Rigging work on the main boom Opening the hook block • Pull out the rods (2). • Fold down the plates (1). Fitting the hoist rope • Pull out the rods (5). • Pull out the rod (3) and push the bracket (4) to the rear.
  • Page 817 Rigging work 11.10 Rigging work on the main boom Reeving the hoist rope A For the main hoist rope B For the auxiliary hoist rope • Guide the hoist rope over the upper head sheave (1) to the lower head sheave (2). •...
  • Page 818 Rigging work 11.10 Rigging work on the main boom Rope end fitting • Insert the rope end fitting (3) at the fixed point (1) and secure the pin (2). Securing the hoist rope • Pull the rod (3) and fold the bracket (4) forwards.
  • Page 819 Rigging work 11.10 Rigging work on the main boom Unreeving hoist rope • Pull out the rod (5). • Remove the retaining pins and pull out the rod (3). Push the bracket (4) to the rear. Insert the rod (3). à...
  • Page 820 Rigging work 11.10 Rigging work on the main boom Blank page 11 - 112 3 302 633 en Operating Instructions GMK5250L...

  • Page 821: Possible Reeving On The Main Boom

    Rigging work 11.10 Rigging work on the main boom 11.10.6 Possible reeving on the main boom Possible reevings on lattice extensions and the auxiliary single-sheave à Operating Instructions Lattice Extension. boom top; The maximum lifting capacity is specified in the Lifting capacity table supplied.
  • Page 822 Rigging work 11.10 Rigging work on the main boom 5 sheave hook block Reeving 11-fall 10-fall 9-fall 8-fall 3 sheave hook block Reeving 7-fall 6-fall 5-fall 4-fall 11 - 114 3 302 633 en Operating Instructions GMK5250L...
  • Page 823 Rigging work 11.10 Rigging work on the main boom 1 sheave hook block Reeving 3-fall 2-fall 1-fall Hook tackle Reeving 1-fall Operating Instructions GMK5250L 3 302 633 en 11 - 115...
  • Page 824 Rigging work 11.10 Rigging work on the main boom With 10 head sheaves 9 sheave hook block Reeving 19-fall 18-fall 17-fall 16-fall 7 sheave hook block Reeving 15-fall 14-fall 13-fall 12-fall 11 - 116 3 302 633 en Operating Instructions GMK5250L...
  • Page 825 Rigging work 11.10 Rigging work on the main boom 5 sheave hook block Reeving 11-fall 10-fall 9-fall 8-fall 3 sheave hook block Reeving 7-fall 6-fall 5-fall 4-fall Operating Instructions GMK5250L 3 302 633 en 11 - 117...
  • Page 826 Rigging work 11.10 Rigging work on the main boom 1 sheave hook block Reeving 3-fall 2-fall 1-fall Hook tackle Reeving 1-fall 11 - 118 3 302 633 en Operating Instructions GMK5250L...
  • Page 827 Rigging work 11.10 Rigging work on the main boom With 11 head sheaves 11 sheave hook block Reeving 22-falls Additional equipment only with special equipment Operating Instructions GMK5250L 3 302 633 en 11 - 119...

  • Page 828: Installing/Removing The Lifting Limit Switch

    Rigging work 11.10 Rigging work on the main boom 11.10.7 Installing/removing the lifting limit switch à For the function of the lifting limit switch; p. 10 - 10. For every reeved hoist rope, you must install a lifting limit switch, attach a lifting limit switch weight and place it around the hoist rope.
  • Page 829 Rigging work 11.10 Rigging work on the main boom If only one lifting limit switch has been installed • Cover the unused socket with the protective cap (1). • Check whether the lock on the lifting limit à Removing the lock , switch (2) is released;...
  • Page 830 Rigging work 11.10 Rigging work on the main boom Attaching the lifting limit switch weight • Attach the lifting limit switch weight (1). If two hoist ropes are reeved, you must attach a lifting limit switch weight to each of the two lifting limit switches.
  • Page 831 Rigging work 11.10 Rigging work on the main boom Removing the This section describes complete removal. lifting limit switch If the hook block is to be subsequently attached to the bumper, you only need to detach the lifting limit switch weight from the hoist rope in order to able to unreeve or re-reeve the hoist rope when unrigging.
  • Page 832 Rigging work 11.10 Rigging work on the main boom Removing the right lifting limit switch • Pull the plug from the socket (1). • Remove the plug (3) from the dummy socket (2) and plug it into the socket (1). •...

  • Page 833: Locking/Unlocking The Lifting Limit Switch

    Rigging work 11.10 Rigging work on the main boom 11.10.8 Locking/unlocking the lifting limit switch Locking If a hoist rope has been reeved and two lifting limit switches are installed, you must lock the lifting limit switch not used in order to enable all crane operations.

  • Page 834: Anemometer And Air Traffic Control Light

    Rigging work 11.10 Rigging work on the main boom 11.10.9 Anemometer and air traffic control light Risk of damage during on-road driving Always remove the anemometer and air traffic control light before on-road driving. This prevents the specified overall height from being exceeded at on-road level, and the anemometer from being damaged due to unfavourable air currents.
  • Page 835 Rigging work 11.10 Rigging work on the main boom Depending on the additional equipment, the truck crane can be equipped with a switchable air traffic control light. This air traffic control light (1) has flashing light and constant light lighting modes. •...
  • Page 836 Rigging work 11.10 Rigging work on the main boom For transport The anemometer has been removed. • Place the rod (1) in the holder (2). • Secure the rod (1) using the retaining pins. 11 - 128 3 302 633 en Operating Instructions GMK5250L...

  • Page 837: Other Rigging Work

    Rigging work 11.11 Other rigging work 11.11 Other rigging work 11.11.1 Railings on the turntable The turntable is equipped with fixed handrails or extendable/retractable handrails, depending on the version. Risk of accidents if railings are not pushed out! The railings provide protection from falling. Always fold out the railings before moving onto the auxiliary hoist.

  • Page 838: Folding The Lighting Carrier In/Out

    Rigging work 11.11 Other rigging work (A) – Folding out • Release the locking bar (2) and swing the railing (1) outward until it engages. (B) – Folding in • Release the locking bar (2) and swing the railing (1) inward until it engages. 11.11.2 Folding the lighting carrier in/out You can fold in the lighting carrier when performing rigging work on the...

  • Page 839: Safety Harness On The Main Boom

    Rigging work 11.11 Other rigging work 11.11.3 Safety harness on the main boom The safety line (1) is fixed securely to the main boom. The safety line consists of two ropes with spacers and wear pads. • Always secure yourself with the safety line and your personal protective equipment when you have to step on the main boom, e.g.
  • Page 840 The weight of the person to be secured must not exceed 140 kg (309 lbs). If you are unsure about which type of fall prevention safety system is required, please contact Manitowoc Crane Care 11 - 132 3 302 633 en...
  • Page 841 Rigging work 11.11 Other rigging work Attaching/detach- ing fall prevention safety system to/ from safety harness Attachment All points designed for fastening a fall prevention safety system are marked with a symbol. • When stepping, observe the following procedure so that you are always secured.
  • Page 842 Rigging work 11.11 Other rigging work Disconnecting Risk of accidents due to incomplete safety system! Only detach the second line of the catch belt once you have reached a secure position on a ladder or access ladder. This will prevent falling due to an incomplete safety system. When stepping, observe the following procedure so that you are always secured.
  • Page 843 Manitowoc Crane Care ised GROVE dealer or your repair crew. The safety harness must always be replaced completely following stress caused by a fall, even if no damage can be detected.

  • Page 844: Slinging Points For Personal Protective Equipment

    Rigging work 11.11 Other rigging work 11.11.4 Slinging points for personal protective equipment The approved slinging points for personal safety equipment are marked with special labels (3). • Always secure your personal safety equipment to the attaching points (1) and (2) when performing rigging work on the main boom, turntable or hoists.

  • Page 845: Cameras For Crane Operation

    Rigging work 11.11 Other rigging work 11.11.5 Cameras for crane operation Camera on For crane operation you have to install the camera and switch it on. main boom For on-road driving, you have to switch the camera off again and remove it. The camera (1) may only be installed on a truck crane equipped with the appropriate receiver (2).
  • Page 846 Rigging work 11.11 Other rigging work Installing • Insert the camera (2) into the clamp (1) and secure it with the retaining pin. • Insert the plug (4) into the socket (3). • Lay the cable (5) so that it will not be damaged.
  • Page 847 Rigging work 11.11 Other rigging work This section describes the CCS display as the monitor. Depending on the Camera on the hoists version, a separate monitor may also be present. Risk of accidents due to exceeding the permissible dimensions! Always retract the camera before driving. When the camera is extended, the overall height specified for on-road driving is exceeded.
  • Page 848 Rigging work 11.11 Other rigging work Operating the camera Switching on • Switch on the ignition. • Select and confirm the symbol (3). The image appears on the display after a few seconds. If an image does not appear; à p.

  • Page 849: Step At The Crane Cab

    Rigging work 11.11 Other rigging work 11.11.6 Step at the crane cab You can control the stair tread via the outrigger control unit or via the Settings menu in the crane control system. Risk of accidents by exceeding the permissible overall width! Always retract the step for on-road driving.
  • Page 850 Rigging work 11.11 Other rigging work Blank page 11 - 142 3 302 633 en Operating Instructions GMK5250L...

  • Page 851: Driving With A Rigged Truck Crane

    Driving with a rigged truck crane 12.1 Driving path Driving with a rigged truck crane This section describes driving the truck crane with the counterweight à Operating Instructions Lattice rigged. If a lattice extension is also rigged; Extension . Risk of accidents due to partially obstructed view of the truck crane! When driving the truck crane, always stay in visual or radio contact with a banksman who can observe the parts you are unable to see, e.g.

  • Page 852: Permissible Rigging Modes And Axle Loads

    Driving with a rigged truck crane 12.2 Permissible rigging modes and axle loads 12.2 Permissible rigging modes and axle loads Depending on the counterweight rigged, you must bring the superstructure and the main boom into certain positions so that the permissible axle loads are not exceeded.
  • Page 853 Driving with a rigged truck crane 12.2 Permissible rigging modes and axle loads Counterweight Telescoping Main Boom Superstruc- Axle load I - II - III - IV - V - VI in t Angle ture position in t (x 1,000 lbs) (lbs) in °...

  • Page 854: Before Driving

    Driving with a rigged truck crane 12.3 Before driving 12.3 Before driving 12.3.1 Secure the superstructure against slewing Danger of overturning by the superstructure slewing whilst driving the truck crane! Always secure the superstructure before driving the rigged truck crane to prevent it slewing.

  • Page 855: Checking The Tyre Pressures And Wind Speed

    Driving with a rigged truck crane 12.3 Before driving 12.3.2 Checking the tyre pressures and wind speed • Ensure that all the tyres are at the prescribed pressure levels; à Tyres , p. 1 - 16. Risk of damage to the tyres! You may only drive the truck crane if the tyres are at the prescribed pressure level.

  • Page 856: Putting The Truck Crane On The Wheels - With Raise Axle Function

    Driving with a rigged truck crane 12.3 Before driving 12.3.3 Putting the truck crane on the wheels – with Raise axle function You can also use the outriggers to put the truck crane on the wheels; à p. 12 - 8. Danger of overturning by unevenly retracting the outrigger cylinders! Retract the outrigger cylinders evenly! This prevents the truck crane from overturning while retracting individual outrigger cylinders.
  • Page 857 Driving with a rigged truck crane 12.3 Before driving Aligning the truck crane • Retract the support cylinders until they do not make contact with the ground during alignment. • Level the truck crane with the Raise axle function. – On the Current inclination display, the marking (1) must be in the middle of the 1°...

  • Page 858: Putting The Truck Crane On The Wheels - With The Outriggers

    Driving with a rigged truck crane 12.3 Before driving 12.3.4 Putting the truck crane on the wheels – with the outriggers You can also use the raise axle function to put the truck crane on the wheels; à p. 12 - 6. Danger of overturning by unevenly retracting the outrigger cylinders! Retract the outrigger cylinders evenly! This prevents the truck crane from overturning while retracting individual outrigger cylinders.
  • Page 859 Driving with a rigged truck crane 12.3 Before driving Levelling the truck crane • Retract the supporting cylinders evenly. Lower the truck crane only to the extent that the suspension struts still have enough play for alignment. • Level the truck crane with the outriggers until only lamp (1) is illuminated in the measuring range 1°.

  • Page 860: Gears/Connections

    Driving with a rigged truck crane 12.3 Before driving 12.3.5 Gears/connections Transmission • In order to – for forward travel in position D, – for reverse travel in position R. An acoustic signal sounds if additional equipment is present. Switching on When driving the rigged truck crane, the separate steering must be à...

  • Page 861: While Driving

    Driving with a rigged truck crane 12.4 While driving 12.4 While driving • Drive only at the lowest possible speed, maximum 1.5 km/h (1 mph). • The turning radius should be as great as possible when driving around corners! • Steer the truck crane when it is moving, and avoid sudden changes to the steering! Risk of damage to the steering linkage...

  • Page 862: After Driving

    Driving with a rigged truck crane 12.5 After driving 12.5 After driving à • Switch separate steering off after driving; p. 5 - 62. • Apply the parking brake. • Support the truck crane with the outrigger span required for the job according to the Lifting capacity table and raise until none of the wheels à...

  • Page 863: Transportation

    Transportation 13.1 Transport with transport vehicle Transportation Transport should be carried out only by qualified heavy transport compa- nies whose personnel are well-acquainted with loads of these dimensions and weights. 13.1 Transport with transport vehicle Risk of accidents due to improper transport! Assign transportation to only qualified companies and ensure that the reg- ulations applicable in the country in which you are working are adhered to.

  • Page 864: Checklist: Checks Before Transport

    Transportation 13.1 Transport with transport vehicle 13.1.1 CHECKLIST: Checks before transport This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there! 1. – All telescopic sections are interlocked; the telescoping cylinder is locked with telescopic section I .
  • Page 865 Transportation 13.1 Transport with transport vehicle à Slew slewable 5. The spotlight must be pivoted downwards (if present); spotlight , p. 8 - 140. 6. The anemometer and air traffic control light are removed; à Anemometer and air traffic control light , p. 11 - 126. à...

  • Page 866: Drive The Truck Crane On To The Transport Vehicle

    Transportation 13.1 Transport with transport vehicle 13.1.2 Drive the truck crane on to the transport vehicle Risk of accidents due to inadequate field of vision! Always have a banksman on hand to help when driving onto a transport vehicle. Maintain eye contact or radio contact with the banksman at all times while driving on to the transport vehicle.

  • Page 867: Slinging Points

    Transportation 13.1 Transport with transport vehicle 13.1.3 Slinging points Risk of accidents due to falling parts! Use only suitable lifting gear with sufficient load bearing capacity and use only the slinging points provided. • Fasten the lifting gear to the slinging points (1) at the front and the slinging points (2) and (3) on both sides.
  • Page 868 Transportation 13.1 Transport with transport vehicle Blank page 13 - 6 3 302 633 en Operating Instructions GMK5250L...

  • Page 869: Malfunctions During Crane Operation

    Malfunctions during crane operation 14.1 Emergency stop switch Malfunctions during crane operation 14.1 Emergency stop switch Risk of overloading if used improperly! Press the emergency stop switch only if it is no longer possible to stop the crane movements with the normal operating elements. The emergency stop switch stops the crane movements suddenly.

  • Page 870: What To Do When Malfunctions Occur During Crane Operation

    • Inform your supervisor. • Try to eliminate the malfunction. Contact if you Manitowoc Crane Care cannot correct the malfunction. • Load cannot be set Secure the danger area using cordons and warning signs. down •...

  • Page 871: Warning And Error Messages

    • Program version Always note down the number of the program version and the serial number after a malfunction occurs before notifying Manitowoc Crane Care • Open the Program version menu (1). 1 Serial number display 2 Program version display 14.3.1...
  • Page 872 CAN bus malfunction • Switch off the ignition and wait about 15 seconds, then switch it on again. If the malfunction is still present, contact Manitowoc Crane Care Engine oil pressure • Switch off the engine as quickly as possible.
  • Page 873 Malfunctions during crane operation 14.3 Warning and error messages Filling up The fuel tank is filled only to a level of approx. 5%. à • Refuel before the fuel is used up; p. 4 - 7. If the fuel tank is almost empty, air will be sucked in and you will have to à...
  • Page 874 Malfunctions during crane operation 14.3 Warning and error messages Pre-tension counterweight The pre-tensioning pressure is too low. à • Pretension the counterweight; p. 11 - 85. Vehicle brake • Stop the truck crane immediately and check the pressure in the brake à...

  • Page 875: Error Messages On The Ccs Display

    Malfunctions during crane operation 14.3 Warning and error messages 14.3.2 Error messages on the CCS Display Risk of accidents! Immediately stop operating the crane if an error message is displayed! The crane control may only be repaired by properly qualified personnel. •...
  • Page 876 • Select and confirm symbol (1) to acknowl- edge the error. If the error cannot be acknowledged, consult . First note the serial Manitowoc Crane Care à number and programme version; p. 14 - 3. Error message display For each error the display shows: –...

  • Page 877: Warning Messages On The Rcl Display

    Malfunctions during crane operation 14.3 Warning and error messages 14.3.3 Warning messages on the RCL display The buzzer tone sounds once when the RCL detects a malfunction. Lamps (3) and (4) light up. A symbol is displayed, e.g. the symbol (1). If several warning messages exist, all of the cor- responding symbols are displayed one after the other in consecutive order.
  • Page 878 Malfunctions during crane operation 14.3 Warning and error messages – Lattice extension angle too small à Operating Instructions Lattice Extension . Raise the main boom; – Lattice extension angle too large Lower the main boom; – Boom angle not measured (different sensor values) –...
  • Page 879 Malfunctions during crane operation 14.3 Warning and error messages – RCL override (switch 3) not actuated – RCL override (switch 3) actuated – RCL override, all switches actuated – Learn-in phase Displayed only during maintenance by service personnel – Data acquisition Displayed only during maintenance by service personnel –...
  • Page 880 Malfunctions during crane operation 14.3 Warning and error messages – Active working range limiter, maximum permissible slewing angle reached – Active working range limiter, maximum permissible working radius reached – Hoist rope travel limitation, upper or lower limit reached – Hoist rope travel limitation, working radius or telescope status changed If the described measures do not solve the problem, try to remedy the error by switching off the ignition and switching it on again after about 15 seconds.

  • Page 881: Finding And Eliminating Malfunctions

    Control unit faulty, error Acknowledge error mes- à message is displayed sage once; p. 14 - 3 – if error persists, notify Manitowoc Crane Care Only the lifting function Lowering limit switch Leave the shutdown works approached range and lift the main...

  • Page 882: Malfunctions In The Hoist Cameras

    If necessary, acknowledge speed mode function not error once and briefly working turn off the ignition – if error persists, notify Manitowoc Crane Care No lifting function Fuse is blown Replace blown fuse; à p. 14 - 63 Lifting or lowering is Speed limited Increase limit;...

  • Page 883: Malfunctions In The Main Boom Camera

    Radio communication Adjust the receiver on the crane between camera and receiver cab. is interrupted. Connection between receiver Check cable connection and and monitor is disconnected. notify Manitowoc Crane Care necessary. Operating Instructions GMK5250L 3 302 633 en 14 - 15...

  • Page 884: Malfunctions On The Derricking Gear

    Acknowledge error mes- à message is displayed sage once; p. 14 - 3 – if error persists, notify Manitowoc Crane Care Lowering function not Lifting limit switch Leave the shutdown working approached, lamp lights up range and lower the auxil-...

  • Page 885: Malfunctions In The Telescoping Mechanism

    Control unit faulty, error Acknowledge error mes- à message is displayed sage once; p. 14 - 3 – if error persists, notify Manitowoc Crane Care Fuse is blown Replace blown fuse; à p. 14 - 63 Telescopic section and Faulty valve Note the error code à...
  • Page 886 Function disabled by CCS If necessary, acknowledge working error once and briefly turn off the ignition – if error persists, notify Manitowoc Crane Care Fuse is blown Replace blown fuse; à p. 14 - 63 Telescoping not possible, Speed limited Increase limit;...

  • Page 887: Malfunctions On The Slewing Gear

    Acknowledge error mes- à sage is displayed sage once; p. 14 - 3 – if error persists, notify Manitowoc Crane Care Rigging mode for the 0° to the Slewing function not Confirm rigging mode for rear position confirmed working a slewing range...

  • Page 888: Malfunctions On The Counterweight Hoist Unit

    – it if occurs again, notify cal error Manitowoc Crane Care Superstructure in the interme- Slew to the Move lifting Lifting cylinder exten- diate position rigging range cylinders or Lift/lower coun-...

  • Page 889: Malfunctions In The Hydraulic System/Hydraulic Oil Cooler

    Pre-selected function cannot Another function has been Pre-select the desired function be performed pre-selected Operation not possible Malfunction in the control must be Manitowoc Crane Care system notified 14.4.11 Malfunctions when inclining the crane cab Malfunction Cause Remedy Crane cab inclination function Fuse is blown Replace blown fuse;...

  • Page 890: Malfunctions Of The Outriggers

    à bridging plug not inserted p. 11 - 22 None of the specified causes Solenoid valves not working must be Manitowoc Crane Care apply notified 14.4.13 Malfunctions when raising the axles Malfunction Cause Remedy...

  • Page 891: Malfunctions On The Ccs/Rcl Control Units

    Malfunctions during crane operation 14.4 Finding and eliminating malfunctions 14.4.14 Malfunctions on the CCS/RCL control units Malfunction Cause Remedy Control unit not working Power supply not switched on Switch on the ignition Fuse F1/4 blown Replace blown fuses; à p. 14 - 63 Display is dark –...
  • Page 892 Malfunctions during crane operation 14.4 Finding and eliminating malfunctions Blank page 14 - 24 3 302 633 en Operating Instructions GMK5250L...

  • Page 893: Emergency Operations And Programs

    Malfunctions during crane operation 14.5 Emergency operations and programs 14.5 Emergency operations and programs This section contains all the information about possible emergency operations and emergency programs. The following are available: – mechanical emergency activation for retracting, – the Telescoping emergency program submenu, –...

  • Page 894: Mechanical Emergency Activation For Retracting

    The best suitable retracting procedures in your particular case depend on the conditions on site and on the crane functions that are still available. Select the procedure best suited to your particular case and consult Manitowoc Crane Care 14 - 26 3 302 633 en...
  • Page 895 Malfunctions during crane operation 14.5 Emergency operations and programs Mechanical emer- The following requirements must be met before unlocking manually: gency activation – The main boom must be lowered to the horizontal position so that the telescopic section cannot retract by itself. –...
  • Page 896 Malfunctions during crane operation 14.5 Emergency operations and programs Unlocking • (A) – Extend approx. 35 mm (0.11 ft) so that the cutout (4) is accessible. • (B) – Screw a a bolt into the hole (1). The locking pins (2) must retract behind the tele- scopic section (3).

  • Page 897: Telescoping Emergency Program

    Malfunctions during crane operation 14.5 Emergency operations and programs 14.5.2 Telescoping emergency program In the event of a malfunction in the telescoping mechanism, you can retract the main boom with the Telescoping emergency program. The emergency program is not intended for crane operation and is there- fore restricted to a certain amount of time.
  • Page 898 Malfunctions during crane operation 14.5 Emergency operations and programs Open the Emer- gency program submenu • Select and confirm the symbol (1) – the Telescoping emergency program is opened. • Select and confirm the symbols (1) to (4). • Confirm the entry with the symbol (5). You can cancel the entry at any time using button (6) or (7).
  • Page 899 If no values are shown on displays (1) and (2) you must not start the telescoping process. Contact Manitowoc Crane Care – If a symbol (3) is violet, there is an error at the proximity switch. The symbols (4) and (5) are active. After selec- tion and confirmation, locking or unlocking is performed immediately.
  • Page 900 Malfunctions during crane operation 14.5 Emergency operations and programs Risk of damage to the main boom! Never telescope the main boom if at the same time there is an error at both the length indicator and the proximity switch. It would then not be possible for you to monitor operations, and compo- nents in the main boom could be damaged, or a situation could arise in which the main boom can no longer be extended or retracted.
  • Page 901 You can select and confirm the symbol for unlocking the telescopic section only a maximum of 2 times. If this does not start the unlocking procedure, contact Manitowoc Crane Care – The telescoping cylinder is at the locking point and is locked, symbols (2) are green.
  • Page 902 You can select and confirm the symbol for unlocking the telescoping cylin- der only a maximum of 2 times. If this does not start the unlocking proce- dure, contact Manitowoc Crane Care • Select and confirm the symbol (1). The telescoping cylinder is now unlocked.
  • Page 903 Malfunctions during crane operation 14.5 Emergency operations and programs Extending and locking the telescoping cylinder You may not select Lock while the telescoping cylinder is retracting or extending. Under no circumstances select and confirm the symbol (1). Risk of damage to the main boom! If you select Lock while the telescoping cylinder is moving, the locking pins on the telescopic section are slid out immediately and they can damage or tear the electrical or hydraulic components in the main boom.
  • Page 904 Malfunctions during crane operation 14.5 Emergency operations and programs Tables for The extent to which the telescoping cylinder has to be extended in order to approaching the reach a locking point depends on whether you want to lock: locking points –...
  • Page 905 Malfunctions during crane operation 14.5 Emergency operations and programs Locking points for the telescopic sections The telescopic section must not be set down for locking or unlocking it. The cutout (1) must be clear. That is why you have to extend the telescoping cylinder further than with a return run.
  • Page 906 Malfunctions during crane operation 14.5 Emergency operations and programs Blank page 14 - 38 3 302 633 en Operating Instructions GMK5250L...

  • Page 907: Entering The Current Telescoping

    Malfunctions during crane operation 14.5 Emergency operations and programs 14.5.3 Entering the current telescoping CCS no longer displays the current telescoping, – if you telescoped in emergency mode, or – if the power supply was interrupted in the course of saving data. In these cases, you must enter the current telescoping, e.g.
  • Page 908 Malfunctions during crane operation 14.5 Emergency operations and programs You can cancel the entry at any time using button (1) or (2). Risk of damage due to incorrect input! Before working with the crane, check whether CCS indicates the current telescoping and correct if this is not the case.

  • Page 909: Emergency Operation With The Hand-Held Control

    Malfunctions during crane operation 14.5 Emergency operations and programs 14.5.4 Emergency operation with the hand-held control If the power units no longer respond to the operating elements in the crane cab, you can operate the power units with the hand-held control. Operating them with the hand-held control is intended for emergencies only and for bringing the truck crane into a safe state or to shut it down.
  • Page 910 Malfunctions during crane operation 14.5 Emergency operations and programs Pre-selecting a power unit • Press the button for the desired power unit once, e.g. the button (1) for the main hoist. When the function is enabled, the lamp in the button lights up. With the telescoping mechanism, teleautomation with the goal 0/0/0/0/0/0 is always selected at the same time –...
  • Page 911 Malfunctions during crane operation 14.5 Emergency operations and programs The following table shows all the button combinations. Actuated buttons are shown in black. Pre-selected power unit Telescoping Derricking Slewing Lattice Button Hoists mechanism gear gear extension combination None Lower boom None Lower Lower boom...
  • Page 912 Malfunctions during crane operation 14.5 Emergency operations and programs Stopping The movement continues until you release the button or the end position is movements reached. You can stop operations with the emergency stop switch if they do not stop by Stopping à...

  • Page 913: Notes On Slewing In Emergency Operation

    Check the table to see if slewing is permitted. Adhere to the enabled work- ing range specified in the lifting capacity table and observe the restrictions described. If you have any doubts, contact Manitowoc Crane Care Rigged outrigger span 8.950 x (29.4 x) 2.710 m 4.310 m 5.910 m...
  • Page 914 If you have any doubts, contact Manitowoc Crane Care When slewing with the hand-held control is unavoidable • Refer to the lifting capacity table (provided in digital form only) for the slewing ranges applicable to the current rigging mode.

  • Page 915: Hydraulic Emergency Operation

    Malfunctions during crane operation 14.6 Hydraulic emergency operation 14.6 Hydraulic emergency operation This section only applies to the standard hydraulic emergency operation. If the truck crane is equipped with an hydraulic emergency operation system à to BGR 159; p. 14 - 51. 14.6.1 Operating principle The hydraulic emergency operation is intended for lifting the main boom...

  • Page 916: Establishing The Hydraulic Circuits Required

    Malfunctions during crane operation 14.6 Hydraulic emergency operation 14.6.2 Establishing the hydraulic circuits required If the Lower movement is to be performed in addition to raising the boom after switching on the energy source, then you must switch over the valves and switch a valve to continuous operation.
  • Page 917 Malfunctions during crane operation 14.6 Hydraulic emergency operation Switching the After switching over the valves, you must additionally switch one valve to continuous opera- continuous operation. tion on and off Switching on continuous operation • Unscrew the cap (2) from valve Y1104 – Lowering (1).

  • Page 918: Connecting/Disconnecting The Energy Source

    Malfunctions during crane operation 14.6 Hydraulic emergency operation 14.6.3 Connecting/disconnecting the energy source Connecting The hoses for the pressure line and suction line are assigned according to the various diameters. • Connect the air traffic control light to the connection (1). •...

  • Page 919: Operating Principle Of Emergency Operation Bgr 159

    Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7 Hydraulic emergency operation as per BGR 159 With this additional equipment, the truck crane is equipped with an hydrau- lic emergency bleed valve in accordance with BGR 159 (4.2.8). This allows small loads to be transported in case of emergency, e.g.

  • Page 920: Connecting/Disconnecting Hoses

    Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 Emergency supply When using an emergency supply, the con- nections (1) feed a transformer (2) that is con- nected to the hydraulic system of the other à Emergency supply of another crane , crane;...
  • Page 921 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 On the superstructure • Connect the thicker hose (4) to the connec- tion (1). • Connect the thicker hose (3) to the connec- tion (2). Disconnecting After the emergency operation, you must disconnect the hoses and the connections transformer.

  • Page 922: Switching Emergency Operation On/Off

    Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 • Remove the hoses (2) from the connec- tions (1). • Close off the hoses and connections with the caps. • Remove the transformer (3). 14.7.3 Switching emergency operation on/off •...

  • Page 923: Establishing The Hydraulic Circuits Required

    Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.4 Establishing the hydraulic circuits required You must switch over the necessary valves to establish a hydraulic circuit. Switching over The valves 1 to 5 are labelled with their respective numbers. valves For crane operation •...
  • Page 924 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 For emergency operation • If necessary, remove the cover over the valves 1 to 5. • Switch the valves 1 to 5 to the positions for the desired crane movement – as shown in the following table.
  • Page 925 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 For lifting/ After establishing the hydraulic circuits you must also: lowering – switch one valve permanently on, – connect one valve to the hoist. Switching on continuous operation Always switch only one valve to continuous operation.
  • Page 926 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 (A) – Emergency operation position • Close the valve 7 – lever (1) at right angles to the line. (B) – Crane operation position • Open the valve 7 – lever (1) parallel to the pipe.

  • Page 927: Performing Emergency Operation

    Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.5 Performing emergency operation If the required hydraulic circuit has been established, you can make the corresponding crane movement. You can control the speed of all power units with the control lever. Slewing It is not possible to control the slewing movements with the control lever for emergency operation with the same degree of sensitivity as with the control...
  • Page 928 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 • Derricking Determine the maximum permissible working radius for the current rigging mode according to Lifting capacity table . Danger of overturning if the working radius is too large when lowering the boom! In emergency operation, operations are not shut down by the RCL.

  • Page 929: After Emergency Operation

    Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.6 After emergency operation You must restore the truck crane to its original state after finishing emergency operation. • Switching off Switch off the engine. emergency operation Switching over to After every emergency operation à...

  • Page 930: Emergency Supply Of Another Crane

    Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.7 Emergency supply of another crane For emergency The hoses are assigned according to the various diameters. supply On the crane to be supplied • Attach the transformer (3). à...

  • Page 931: Fuses In The Crane Cab

    If a fuse with the same amperage fails again once the ignition is switched on, then notify Manitowoc Crane Care Risk of fire! Never repair a blown fuse with other electrically conductive materials. Operating Instructions GMK5250L...
  • Page 932 Malfunctions during crane operation 14.8 Fuses in the crane cab • Loosen the bolts (2) and remove the cover (1). The fuse groups F1 to F8 consist of eight fuses each. The following tables show the designations of the individual fuses, including their amperage and functions.
  • Page 933 Malfunctions during crane operation 14.8 Fuses in the crane cab Designation Amperage (A) Function F2/1 Control unit UB 1 IOL 30 F2/2 Control unit UB 2 IOL 30 F2/3 Control unit UB 2 IOL 30 F2/4 Control unit UB 1 IOL 34 F2/5 Control unit UB 2 IOL 34 F2/6...
  • Page 934 Malfunctions during crane operation 14.8 Fuses in the crane cab Designation Amperage (A) Function Control unit UE IOL 30 F4/1 Control unit CCM 10 Control units IOS 20 and IOS 22 F4/2 – Unassigned F4/3 CraneSTAR system F4/4 Radio F4/5 –...
  • Page 935 Malfunctions during crane operation 14.8 Fuses in the crane cab Designation Amperage (A) Function F6/1 Windscreen wiper/washing system Cigarette lighter F6/2 Socket 12 V F6/3 Crane cab spotlight Main boom spotlight F6/4 Spotlight adjustment F6/5 Houselock F6/6 CraneSTAR system F6/7 Remote control F6/8 Camera system...
  • Page 936 Malfunctions during crane operation 14.8 Fuses in the crane cab Blank page 14 - 68 3 302 633 en Operating Instructions GMK5250L...
  • Page 937 Index Index To avoid making the index unnecessarily long and unclear, we have not included every single element from the instrument panel. These elements, such as switches and buttons, lamps and displays are described and named in detail in the overviews of the Chapter 3 and Chapter 8 Truck Crane Description .
  • Page 938 Index Blank page 15 - 2 3 302 633 en Operating Instructions GMK5250L...
  • Page 939 Index Access ladders on the carrier ......... . . 4 - 4 Adjusting the mirrors for driving .
  • Page 940 Index Cameras for crane operation On the driver's cab ..........11 - 139 on the hoists .
  • Page 941 Index Retracting the outriggers ......... . 11 - 39 rigging for crane operation .
  • Page 942 Index Standard heating system ......... 10 - 147 Ventilating .
  • Page 943 Index Air-conditioning system ......... . . 5 - 66 Auxiliary water heater .
  • Page 944 Index display and operating elements in the crane cab ..... . 8 - 139 Operating elements in the driver's cab ....... 3 - 50 Emergency operation Hydraulic emergency operation after emergency operation .
  • Page 945 Index Malfunctions ........... . . 7 - 17 Operation in the driver's cab Checking after starting .
  • Page 946 Index Hoist rope Checking the position ..........10 - 6 positioning and reeving in .
  • Page 947 Index Level adjustment system Changing the vehicle level ......... 5 - 54 Exiting the menu .
  • Page 948 Index Switching off ........... . 10 - 78 Malfunctions Carbamide system .
  • Page 949 Index Hand-held control ........8 - 94, 8 - 98 CHECKLIST - extending .
  • Page 950 Index Parking brake Operating elements ..........3 - 63 While towing .
  • Page 951 Index Counterweight ..........11 - 67 Main boom Attaching the hook block to the bumper .
  • Page 952 Index Slewing gear brake Applying ........... 10 - 118 detaching .
  • Page 953 Index Locking the telescopic section ....... . . 10 - 108 Locking the telescopic section for on-road driving .
  • Page 954 Index operation from the driver's cab ........5 - 50 While towing .
  • Page 955 Index Manual ........... . 10 - 140 Entering limit values by approaching them For slewing angles .
  • Page 956 Index Blank page 15 - 20 3 302 633 en Operating Instructions GMK5250L...

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