Manitowoc GROVE GMK5150L Operating Manual

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Operating manual

3 302 709 en

12.01.2018

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Summary of Contents for Manitowoc GROVE GMK5150L

Page 1 Operating manual 3 302 709 en 12.01.2018...
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 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 4 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 5 Driving from the crane cab Crane movement partially blocked Notwithstanding the information in the operat- ing manual supplied, crane movements are blocked during travel. After switching over to driving position – symbol (1) green – the symbol (2) remains grey and the crane hydraulics driving position is switched off.
Page 6 Blank page 3 302 706 en Additional page GMK...
Page 7 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 8 Blank page 3 302 808 en Additional pages GMK...
Page 9 Hook blocks Change / correction to the technical data Contrary to the information in the operating manual supplied, various hook Revision blocks are no longer available. Hook blocks with ballast plates The hook blocks with ballast plates are no longer available. A 3-sheave hook block (light) and a 1-sheave hook block (light) are offered as replacements.
Page 10 Correction to the technical data Standard versions The hook blocks available are listed in the table with the technical data. Length x width x height Weight Load bearing (L) x (W) x (H) Designation in kg capacity in t in m (lbs) (ft) Double hook...
Page 11 Versions as execution as separable hook block Section 1.80 1.00 1.00 Length in m (ft) (5.90) (3.30) (3.30) 0.65 0.60 0.65 Width in m (2.15) (1.95) (2.15) 0.40 0.35 0.40 Height in m (1.30) (1.15) (1.30) Weight in kg (lbs) (2,095) (705) (1,390)
Page 12 Blank page 3 302 834 en-us Correction sheet GMK5150/GMK5150L...
Page 13 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 14 Blank page 3 302 839 en Additional pages GMK...
Page 15 The operating manual consists 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 Transport 8 Malfunctions in driving mode 9 Operating elements for crane operation 10 Starting/switching off the engine –...
Page 16 3 302 709 en Operating manual GMK5150L...
Page 17: Table Of Contents
Manitowoc Crane Care ........
Page 18 3 302 709 en Operating manual GMK5150L...
Page 19 Basic safety instructions Intended use ............2 - 2.1.1 Improper use .
Page 20 3 302 709 en Operating manual GMK5150L...
Page 21 Operating elements for driving Overview of the operating elements ........3 - 3.1.1 On the outside of the truck crane .
Page 22 3.2.22 Front flap ............3 - 73 3.2.23 Windows and doors .
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 3 302 709 en Operating manual GMK5150L...
Page 25 Driving Before driving ............5 - 5.1.1 CHECKLIST: checks before on-road driving .
Page 26 5.6.2 Air-conditioning system ..........5 - 68 5.6.3 Auxiliary water heating system .
Page 27 Driving modes and rigging for on-road driving Driving modes ............6 - 6.1.1 How to use the tables .
Page 28 6.6.4 Preparations – for removal......... . 6 - 56 6.6.5 Preparations –...
Page 29 Transport Transport with transport vehicle ........7 - 7.1.1 CHECKLIST: Checks before transport .
Page 30 3 302 709 en Operating manual GMK5150L...
Page 31 Malfunctions in driving mode Emergency stop switch ..........8 - Procedure during malfunctions .
Page 32 3 302 709 en Operating manual GMK5150L...
Page 33 Operating elements for crane operation Overview of the operating elements ........9 - 9.1.1 Exterior of the truck crane .
Page 34 9.2.17 Derricking gear ........... 9 - 120 9.2.18 Telescoping mechanism.
Page 35 Starting/switching off the engine – for crane operation 10.1 When starting the engine for the first time in the day ....10 - 10.2 Starting the engine –...
Page 36 3 302 709 en Operating manual GMK5150L...
Page 37 Crane operation 11.1 Before operating the crane ......... . . 11 - 11.1.1 CHECKLIST: Checks before operating the crane .
Page 38 11.6 Settings and displays for crane operation ......11 - 123 11.6.1 Inclining the crane cab .
Page 39 Rigging work 12.1 Rigging work checklists for crane operation with the main boom ..12 - 12.1.1 CHECKLIST: Rigging ..........12 - 12.1.2 CHECKLIST: Unrigging .
Page 40 12.9.2 Counterweight sections ......... . . 12 - 73 12.9.3 Identification .
Page 41 Driving with a rigged truck crane 13.1 Route ............13 - 13.2 Permissible rigging modes and axle loads .
Page 42 3 302 709 en Operating manual GMK5150L...
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 14.7.3 CHECKLIST: After emergency operation......14 - 62 14.7.4 Connecting/removing transformer – for self-sufficiency ....14 - 63 14.7.5 Switching emergency operation on/off.
Page 45 Index Operating manual 3 302 709 en GMK5150L...
Page 46 3 302 709 en Operating manual GMK5150L...
Page 47: Overview
In the event 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. Observe to the requirements regarding the obligation to report accidents...
Page 48 Overview 1.1 Accidents Blank page 1 - 2 3 302 709 en Operating manual GMK5150L...
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 3 302 709 en Operating manual GMK5150L...
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 3 302 709 en Operating manual GMK5150L...
Page 53: Technical Data
Overview 1.5 Technical data Technical data GROVE crane GMK5150L Permissible temperature range: -25 °C to +40 °C (-13 °F to +104 °F) Crane designation: Truck crane as per DIN 15 001, Part 1 Crane application: Service crane as per DIN 15 001, Part 2 Crane classification: Hoist class H1 to DIN 15 018, Part 1 Crane class A1 to ISO 4301, Part 2...
Page 54: Dimensions And Weights Of The Truck Crane, Axle Loads
Overview 1.5 Technical data 1.5.2 Dimensions and weights of the truck crane, axle loads All dimensions in the illustration are in mm. 1 - 8 3 302 709 en Operating manual GMK5150L...
Page 55 Overview 1.5 Technical data à Dimensions All dimensions relate to on-road mode; Driving modes , p. 6 - 1. Length without auxiliary hoist: 14.46 m (47.4 ft) Height: At on-road level: – 385/95 R25 3.95 m (12.9 ft) – 445/95 R25; 525/80 R25 3.99 m (13.1 ft) Max.
Page 56: Dimensions And Weights Of Removable Parts
Overview 1.5 Technical data 1.5.3 Dimensions and weights of removable parts This section contains the dimensions and weights of the parts that can be à Driving modes , p. 6 - 1. removed for on-road driving; Spare wheel Length x width x height Weight Description in m (ft)
Page 57 Overview 1.5 Technical data Hook blocks and hook tackle Versions as execution as separable hook block Dimensions (m) and weights (kg) 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)
Page 58 Overview 1.5 Technical data Standard versions Length x width x height Weight Description (L) x (W) x (H) In kg (lbs) in m (ft) Single or double hook, 1.50 x 0.55 x 0.40 1,600 8 sheaves (4.90 x 1.80 x 1.30) (1,325) Single or double hook, 1.40 x 0.55 x 0.30...
Page 59 Overview 1.5 Technical data Versions with ballast plate – Version A (1) x (2) x (3) Weight Description in m In kg Hook block 1.41 x 0.56 x 0.44 (4.63 x 1.84 x 1.44) 1 sheave with ballast plates Hook block 1.41 x 0.56 x 0.35 (4.63 x 1.84 x 1.15) 1 sheave without ballast...
Page 60 Overview 1.5 Technical data Counterweight The stability of the crane rigged with the counterweight sections delivered parts has been tested. Counterweight – Version 1 Length x width x Weight Item Description height in m (ft) in kg (lbs) 1.58 x 1.93 x 1.17 2,300 2,3 t base plate (5.18 x 6.33 x 3.84)
Page 61 Overview 1.5 Technical data Counterweight – Version 2 Length x width x Weight Item Description height in m (ft) in kg (lbs) 1.58 x 1.93 x 1.17 2,300 2,3 t base plate (5.18 x 6.33 x 3.84) (5,070) 1.79 x 2.73 x 0.20 2,300 2,3 t-plate (5.87 x 8.96 x 0.52...
Page 62 Overview 1.5 Technical data Counterweight – Version 3 Length x width x Weight Item Description height in m (ft) in kg (lbs) 1.58 x 1.93 x 1.17 2,300 2,3 t base plate (5.18 x 6.33 x 3.84) (5,070) 1.80 x 2.73 x 0.16 2,300 2,3 t-plate (5.91 x 8.96 x 0.56...
Page 63: Carrier
Overview 1.5 Technical data 1.5.4 Carrier Engine Mercedes Benz à – Engine emissions: Engine data card à – Power: Engine data card Fuel – Tank 2 x 200 l (2 x 52.8 gal) AdBlue tank: 40 ltr (10.6 gal) For additional equipment: 2 x 325 l (85.9 gal) Transmission Mercedes G280 –...
Page 64 Overview 1.5 Technical data Steering Dual-circuit hydraulic steering with engine-independent emergency steering pump Tyres 8 x 385/95 R 25 on disc wheels 9.50-25/1.7 8 x 445/95 R 25 on disc wheels 11.00-25/1.7 8 x 525/80 R 25 on disc wheels 17.00-25/1.7 Additional equipment Torque for wheel nuts: 650 Nm (480 lbf ft).
Page 65 Overview 1.5 Technical data Outrigger Design: 4-point telescoping outrigger system Control system: Can be controlled from both sides on the carrier and individ- ually from the crane cab Outrigger span Metre (ft) Per cent (standard): 8.030 x 7.600 m (26.3 x 24.9 ft) 100% 8.030 x 6.700 m (26.3 x 22.0 ft) 8.030 x 5.900 m (26.3 x 19.4 ft)
Page 66 Overview 1.5 Technical data Electrical system Alternator: 28 V / 100 A Batteries: 2 each of 12 V/180 Ah Voltage: 24 V Tool 1 tool kit in tool box, wheel chocks (number according to national regulations) Towing couplings Front towing coupling: 100 kN (22,480 lbf) permissible tension Rear tow lug: 75 kN (16,860 lbf) permissible tension...
Page 67: Superstructure
Overview 1.5 Technical data 1.5.5 Superstructure Main hoist Drum diameter: 391 mm (15.39 in) Rope diameter: 19 mm (0.75 in) Rope length: 255 m (836 ft) Rope pull: 76.4 kN/line (17,175 lbf) Power unit group: M 3 (to ISO 4301 - 2) Load spectrum: Load spectrum factor: Km = 0.125...
Page 68 Overview 1.5 Technical data Main boom Main boom lengths: 11.4 m to 60.0 m (37.4 ft to 196.9 ft) Main boom head: 6 sheaves 8 sheaves Cylinder: One single-level telescoping cylinder with locking/unlocking mechanism Power unit group Telescoping mechanism: M 1 (to ISO 4301 - 2) Additional equipment à...
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, for example, damage to the truck crane or other parts which are located within the working range. This symbol warns you about situations where there is a danger of 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 8 contain a description of how to drive the truck crane. – The chapters 9 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, texts and cross-references in this section are only an example example and may differ from the conditions on your truck crane. 1 - 30 3 302 709 en Operating manual GMK5150L...
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 and vice versa when the truck crane is being used in countries that use US units of measurement. Converting from into Multiply by...
Page 80 Overview 1.8 Conversion table for US measuring units Blank page 1 - 34 3 302 709 en Operating manual GMK5150L...
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 3 302 709 en Operating manual GMK5150L...
Page 83 Overview 1.10 Identification The following plates and numbers are attached to the truck crane for iden- tification purposes: 1 Serial number and crane type 2 The CE mark, which is only applicable for truck cranes whose equip- ment and configuration complies with the guidelines and standards specified in the supplied EC Declaration of Conformity.
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 GMK5150L 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 GMK5150L. The manufacturer is not liable for any damage caused by improper or unau- thorized use of the GMK5150L 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 GMK5150L truck crane. The user alone bears the risk. Improper use includes: – Transporting loads on the carrier –...
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 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 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 After a lightning strike, always have the truck crane checked by before you operate the truck crane – even if you Manitowoc Crane Care do not notice any impairment to its function. Electronic components may be damaged by a lightning strike and may fail unexpectedly, either immediately or during later operation.
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 9. Overview of the operating elements This section shows the position and designation of the operating elements for driving.
Page 98: On The Outside Of The Truck Crane
Operating elements for driving 3.1 Overview of the operating elements 3.1.1 On the outside of the truck crane 3 - 2 3 302 709 en Operating manual GMK5150L...
Page 99 Operating elements for driving 3.1 Overview of the operating elements à 1 Front flap p. 3 - 73 à 2 Driver's cab p. 3 - 6 1), 2) 3 Hose drum, installing/removing à 4 Engine for driving p. 4 - 1 à...
Page 100 Operating elements for driving 3.1 Overview of the operating elements 3 - 4 3 302 709 en Operating manual GMK5150L...
Page 101 Operating elements for driving 3.1 Overview of the operating elements à 17 Raising/lowering the 3rd axle line for dolly p. 6 - 15 operation à 18 AdBlue tank p. 4 - 7 à 19 – Starting the truck crane externally p.
Page 102: Driver's Cab
Operating elements for driving 3.1 Overview of the operating elements 3.1.2 Driver's cab Front overview 3 - 6 3 302 709 en Operating manual GMK5150L...
Page 103: 15 Steering Column/Steering Wheel
Operating elements for driving 3.1 Overview of the operating elements à 1 Adjusting the passenger seat p. 5 - 14 à 2 Rear overview p. 3 - 8 3 Warning triangle, first-aid kit, warning lamp, high-vis vest à 4 Auxiliary air heater p.
Page 104 Operating elements for driving 3.1 Overview of the operating elements Rear overview à 1 Fold-up berth p. 5 - 48 2 Rest 3 Storage (spare key etc. (on delivery)) 4 Storage compartment (e.g. for battery charger) Additional equipment 3 - 8 3 302 709 en Operating manual GMK5150L...
Page 105 Operating elements for driving 3.1 Overview of the operating elements Behind the cover à 1 Fuses in the driver's cab p. 8 - 50 Operating manual 3 302 709 en 3 - 9 GMK5150L...
Page 106: Transmission Operating Elements
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 - 72 2 Control: à – Set idling speed p. 3 - 42 à – Setting cruise control p.
Page 107 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 - 66 à 2 Separate manual steering p. 3 - 61 à 3 Battery master switch p. 3 - 45 à...
Page 108 Operating elements for driving 3.1 Overview of the operating elements Middle 3 - 12 3 302 709 en Operating manual GMK5150L...
Page 109: On-Board Computer
Operating elements for driving 3.1 Overview of the operating elements à 1 Indicator lamp for turn signal indicator p. 3 - 66 à 2 Indicator lamp for trailer turn signal indicator p. 3 - 66 à 3 Speedometer p. 3 - 70 à...
Page 110 Operating elements for driving 3.1 Overview of the operating elements 3.1.5 Transmission operating elements 1 Selecting the driving direction 2 Changing the operating mode à 3 Shift down, manual p. 3 - 49 4 Shift up, manual 5 Gear indicator 3 - 14 3 302 709 en Operating manual...
Page 111 Operating elements for driving 3.1 Overview of the operating elements 3.1.6 On-board computer 1 Main menu display 2 Display menu – Name à 3 Submenu display p. 3 - 72 4 Display area 5 Display information Operating manual 3 302 709 en 3 - 15 GMK5150L...
Page 112: Tachograph
Operating elements for driving 3.1 Overview of the operating elements 3.1.7 Tachograph à p. 5 - 18 (A) – Tachograph à 1 Display p. 5 - 21 à 2 Time correction - : p. 3 - 70 à 3 Time correction + : p.
Page 113: Heating And Air-Conditioning System
Operating elements for driving 3.1 Overview of the operating elements 3.1.8 Heating and air-conditioning system Standard à 1 Setting the fan p. 5 - 65 à 2 Air distribution p. 5 - 66 à 3 Setting the temperature p. 5 - 65 à...
Page 114 Operating elements for driving 3.1 Overview of the operating elements Auxiliary water heating system à 1 Auxiliary water heating system p. 5 - 70 à – Preheating the engine p. 5 - 70 à – Preheating the driver's cab p. 5 - 71 3 - 18 3 302 709 en Operating manual...
Page 115 Operating elements for driving 3.1 Overview of the operating elements Auxiliary air heater à 1 Selecting a function p. 5 - 76 2 Menu line 3 Program column 4 Display line à 5 – Switching on p. 5 - 76 à...
Page 116 Operating elements for driving 3.1 Overview of the operating elements Blank page 3 - 20 3 302 709 en Operating manual GMK5150L...
Page 117: Ccs Control Unit
Operating elements for driving 3.1 Overview of the operating elements 3.1.9 CCS control unit 1 CCS display à Overview start menu p. 3 - 23 à 2 Service/diagnosis connection p. 3 - 71 à 3 Exiting the menu/input mode p. 3 - 47 à...
Page 118: 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 - 57 à Longitudinal differential lock display p. 3 - 57 à 2 Display of retarder function on/off p.
Page 119: 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 2 Serial number display à 3 Display of transverse and longitudinal differential p. 3 - 28 locks on/off à 4 Voltage monitoring display p.
Page 120: Ccs - Overview Menu Groups
Operating elements for driving 3.1 Overview of the operating elements 3.1.12 CCS – Overview menu groups 3 - 24 3 302 709 en Operating manual GMK5150L...
Page 121 Operating elements for driving 3.1 Overview of the operating elements à 1 Carrier menu group p. 3 - 26 – Suspension/level adjustment menu – Driving menu à 2 Settings menu group p. 3 - 29 – Set display brightness and date/time menu –...
Page 122: 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 - 27 à 2 Driving menu p. 3 - 28 3 - 26 3 302 709 en Operating manual GMK5150L...
Page 123 Operating elements for driving 3.1 Overview of the operating elements Suspension/level adjustment menu à 1 Front level pre-selection p. 3 - 68 à 2 Level adjustment system enabled display p. 3 - 68 à 3 Suspension operation pressure gauge p. 3 - 64 à...
Page 124 Operating elements for driving 3.1 Overview of the operating elements Driving menu à 1 Current wheel position display p. 3 - 63 à 2 – Transverse differential locks display p. 3 - 57 à – Transverse differential locks on/off p. 3 - 57 à...
Page 125: 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 - 30 à 2 Switch units menu p. 3 - 31 à 3 Lamp test p. 4 - 10 Operating manual 3 302 709 en 3 - 29...
Page 126 Operating elements for driving 3.1 Overview of the operating elements Set display brightness and date/time menu à 1 Selection setting the display brightness p. 4 - 11 à 2 Increasing/reducing the value p. 4 - 11 à 3 Display in percentage p.
Page 127 Operating elements for driving 3.1 Overview of the operating elements Switch units menu à 1 Display units in: p. 5 - 64 – Metres – Degrees Celsius – Kilograms – Bar à 2 Display units in: p. 5 - 64 –...
Page 128: Menu Group Information
Operating elements for driving 3.1 Overview of the operating elements 3.1.15 Menu group Information à 1 Operating hours menu p. 3 - 33 à 2 Engine error menu p. 3 - 34 à 3 Crane operation error menu p. 3 - 35 3 - 32 3 302 709 en Operating manual...
Page 129 Operating elements for driving 3.1 Overview of the operating elements Operating hours menu à 1 Keycode input p. 5 - 24 à 2 Carrier p. 5 - 24 à 3 Engine p. 5 - 24 à 4 Transmission p. 5 - 24 à...
Page 130 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. 8 - 17 4 Error code display 5 Previous error 6 Next error 3 - 34 3 302 709 en...
Page 131 Operating elements for driving 3.1 Overview of the operating elements Crane operation error menu 1 Current errors/total errors display 2 Error code à 3 Deleting errors p. 8 - 17 4 Next error 5 Previous error Operating manual 3 302 709 en 3 - 35 GMK5150L...
Page 132: Various Controls Menu Group
Operating elements for driving 3.1 Overview of the operating elements 3.1.16 Various controls menu group à 1 Outrigger lighting on/off p. 3 - 67 à 2 Reverse camera on/off p. 3 - 52 3 - 36 3 302 709 en Operating manual GMK5150L...
Page 133: Emergency Operations Menu Group
Operating elements for driving 3.1 Overview of the operating elements 3.1.17 Emergency operations menu group à 1 Switching emergency operation on/off p. 14 - 65 à 2 Switching towing mode on/off p. 8 - 31 (Transfer case for off-road gear on/off) à...
Page 134: Outrigger Control Units
Operating elements for driving 3.1 Overview of the operating elements 3.1.18 Outrigger control units à Outriggers control units , Contain operating elements for crane operation; p. 9 - 85. 3 - 38 3 302 709 en Operating manual GMK5150L...
Page 135: Short Description Of The Operating Elements
If some operating elements do not work, first read the following chapters which are referred to at the respective places before contacting Manitowoc Crane Care Operating manual 3 302 709 en 3 - 39...
Page 136: Definition Of Information Relating To Directions Of Movement
Operating elements for driving 3.2 Short description of the operating elements 3.2.1 Definition of information relating to directions of movement Basic rule Directions always depend on whether the carrier or the superstructure 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 137: General Rules For Buttons And Symbols On The Display
Operating elements for driving 3.2 Short 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 138: Engine
Operating elements for driving 3.2 Short 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 3 Starting position à...
Page 139 Operating elements for driving 3.2 Short description of the operating elements Setting cruise control 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 140: Adblue System
Operating elements for driving 3.2 Short description of the operating elements 3.2.4 AdBlue system Instrument panel AdBlue warning – Out: Filling level sufficient, no fault – On: AdBlue system malfunction – Flashing: Adblue tank empty or fault à p. 5 - 45 Torque reduction indicator lamp –...
Page 141: Battery Master Switch
Operating elements for driving 3.2 Short description of the operating elements CCS display Adblue filling level indicator – 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 142: Electrical System
Operating elements for driving 3.2 Short description of the operating elements 3.2.6 Electrical system 12 V power socket on/off – Switch on: Press in switch (1) at the top – Switch off: Press in switch (1) at the bottom Sockets 12 V/24 V 1 Socket 24 V/max.
Page 143: Crane Control Ccs
Operating elements for driving 3.2 Short description of the operating elements 3.2.7 Crane control CCS The GMK5150L truck crane is equipped with the CCS electronic crane control 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 144 Operating elements for driving 3.2 Short 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 145: Transmission
Operating elements for driving 3.2 Short description of the operating elements Selecting / deselecting favourites Several symbols can be selected as favourites. The cursor jumps directly from favourite to favourite when scrolling through the menu groups. Select A symbol is selected, such as symbol (2). 1 Press The symbol is marked as a favourite.
Page 146 Operating elements for driving 3.2 Short description of the operating elements – Position R: When at a standstill – Select reverse starting gear When driving in reverse – No gear change When driving forwards – Select neutral Gearshift lever The truck crane may be stationary or driving. Change over between automatic and manual –...
Page 147 Operating elements for driving 3.2 Short description of the operating elements Display, driving mode Transmission display 1 Currently engaged gear – forwards (1 to 16), for example 6 2 Neutral position switched on 3 Gear currently engaged – 1st reverse gear 4 Gear currently engaged –...
Page 148: Reverse Camera
Operating elements for driving 3.2 Short 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. Switching on – Automatically, when reversing (1), –...
Page 149: 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 displayed.
Page 150 Operating elements for driving 3.2 Short 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 151: Transfer Case
Operating elements for driving 3.2 Short description of the operating elements 3.2.11 Transfer case à Transfer case – switching the off-road gear on/off , p. 5 - 50 Driving menu Opening: Select symbol (1) and confirm – menu is opened Transfer case for off-road gear on/off –...
Page 152 Operating elements for driving 3.2 Short description of the operating elements Blank page 3 - 56 3 302 709 en Operating manual GMK5150L...
Page 153: Final Drive
Operating elements for driving 3.2 Short description of the operating elements 3.2.12 Final drive à Longitudinal and transverse differential locks , p. 5 - 51 Driving menu Opening: Select symbol (1) and confirm – menu is opened Transverse differential locks on/off –...
Page 154: Brakes
Operating elements for driving 3.2 Short description of the operating elements 3.2.13 Brakes Service brake The braking force can be continuously adjusted with the parking brake lever. 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 –...
Page 155 Operating elements for driving 3.2 Short description of the operating elements Instrument panel Additional brake indicator lamp – On: Additional brake on – Out: Additional brake off – Flashing: – Ignition on – Multipurpose switch not in position 0 – Engine is running – retarder power reduced Parking brake 1 To engage the Pull the lever down until it locks into place...
Page 156: Steering/Separate Steering
Operating elements for driving 3.2 Short description of the operating elements 3.2.14 Steering/separate steering à Separate steering , p. 5 - 59 Instrument panel Steering circuit 1 warning Steering circuit 2 warning – On: Engine off – ignition on Engine on – fault, stop – check oil loss –...
Page 157 Operating elements for driving 3.2 Short description of the operating elements Steering system warning 1 After switching on the ignition – Lit – goes out after about three seconds if there is no error Whilst driving – Lit – symbol (2) red Steering system faulty! 3.
Page 158 Operating elements for driving 3.2 Short description of the operating elements CCS display Steering system malfunction/warning The display (1) is shown in the Driving menu and in the Start menu . 1 – Yellow: Steering system malfunction – lamp (3) lit –...
Page 159 Operating elements for driving 3.2 Short description of the operating elements Separate steering crab travel mode on/off – Switch on: Select symbol (1) and confirm – Symbol (2) is displayed – Switch off: Select a different steering mode – Symbol (3) à...
Page 160: Suspension
Operating elements for driving 3.2 Short description of the operating elements 3.2.15 Suspension CCS display Suspension display Suspension on/off – To switch on: Select symbol (1) and confirm – Symbol (2) green (on-road driving) Suspension on – enabled for on-road driving –...
Page 161: Lighting/Windscreen Wipers/Horn
Operating elements for driving 3.2 Short description of the operating elements 3.2.16 Lighting/windscreen wipers/horn Steering column Multipurpose switch Headlight flasher/headlight – full beam 1 Parking light/headlight: Middle position 2 Flash the headlights: Upwards The parking light/headlight must be switched on: 3 Headlight –...
Page 162 Operating elements for driving 3.2 Short description of the operating elements Indicator lamp for turn signal indicator 1 – Flashing: Turn signal indicator on – Out: Turn signal indicator off, or turn signal indicator on and filament lamp faulty Indicator lamp for trailer turn signal indicator 1 –...
Page 163 Operating elements for driving 3.2 Short description of the operating elements Checking headlight – On: Headlight on – Out: Headlight off Rotating beacon on/off – Switch on: Push up – Switch off: Push down CCS display Outrigger lighting on/off – Switch on: Select and confirm symbol (2) –...
Page 164: Level Adjustment System
Operating elements for driving 3.2 Short description of the operating elements 3.2.17 Level adjustment system à Operating the level adjustment system , p. 5 - 53. Suspension/level adjustment menu – Opening: Select symbol (1) and confirm – menu is opened Lift/lower preselection level The suspension must be switched on Select and confirm the corresponding symbol.
Page 165 Operating elements for driving 3.2 Short description of the operating elements Vehicle level display The current status is shown using different symbols. 1 On-road level 2 Off-road level 3 Error 4 Operation pressure in the suspension struts à p. 5 - 53 Setting the on-road level The suspension is switched on.
Page 166: Tachograph/Speedometer
Operating elements for driving 3.2 Short description of the operating elements 3.2.18 Tachograph/speedometer à Setting the tachograph , p. 5 - 18. 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 167: Diagnostics
3.2 Short description of the operating elements 3.2.19 Diagnostics The diagnostics connections may only be operated by service staff from the engine manufacturer/transmission manufacturer, or by Manitowoc Crane Care The following connections are below the cover (4) 1 Carrier electronics diagnostics 2 Transmission diagnostics 3 Engine diagnostics 3.2.20...
Page 168 Operating elements for driving 3.2 Short description of the operating elements 3.2.21 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 169 Operating elements for driving 3.2 Short description of the operating elements Tour data menu 1 Total mileage 2 Daily mileage 3 Time 4 Outside temperature 3.2.22 Front flap Opening • Fold up the front flap (1). • Fasten the support (2) in the clamp (3). Closing •...
Page 170 Operating elements for driving 3.2 Short description of the operating elements 3.2.23 Windows and doors Window winder Risk of crushing when closing the windows If the window winders encounter resistance, they do not stop but keep on moving at reduced power. Button assignment A Window winder, driver's door B Window winder, passenger door...
Page 171 Operating elements for driving 3.2 Short description of the operating elements Doors The same key is used for the driver's and passenger's 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 172 Operating elements for driving 3.2 Short description of the operating elements Blank page 3 - 76 3 302 709 en Operating manual GMK5150L...
Page 173 Operating elements for driving 3.2 Short description of the operating elements 3.2.24 Access ladders and ladders Different ladders and handles are on the truck crane depending on the version. Hazard due to unsecured ladders Always secure the ladders before driving. The prevents the ladders falling down or folding out whilst driving and thus endangering other vehicles.
Page 174 Operating elements for driving 3.2 Short description of the operating elements – Folding in • Release the spring latch (5) and push in the access ladder (4). • Lift the locking bar (3) for releasing and fold the ladder (2) upwards. •...
Page 175 Operating elements for driving 3.2 Short description of the operating elements Folding ladder – shelf under the driver's cab à For the shelf on the rear of carrier; p. 3 - 78. – For the use Ladder (1) – to erect and fold out. •...
Page 176 Operating elements for driving 3.2 Short description of the operating elements Blank page 3 - 80 3 302 709 en Operating manual GMK5150L...
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. 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 - 9. à 5. Check that all emergency stop switches have been reset; p.
Page 179 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 10. Check the fluid supply: à – Fuel tank , p. 4 - 5, à – AdBlue tank , p. 4 - 7 à...
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 in low outside temperatures: 1. The fuel and engine oil must be suitable for use at the respective à...
Page 181: Filling Up
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.3 Filling up à Fuel tank Only use permissible consumables; Separate engine operating instructions, provided by the manufacturer . Danger of fire due to flammable gases Switch off the engine, the heater and all additional heaters before refuelling.
Page 182 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 183 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab AdBlue tank AdBlue is a consumable for exhaust gas treatment. For AdBlue, there are registered trademarks of Kruse GmbH & Co KG, BASF SE and the German Association of the Automotive Industry.
Page 184: Checks Before Starting The Engine
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab If the AdBlue tank is empty, a warning will be output and the engine torque à Overriding torque reduction , p. 5 - 45. will be reduced;...
Page 185: Switch The Ignition On
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 • Press switch (1) up – the battery master switch will be switched on.
Page 186: 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 4.1.6 Lamp test/equalisation of the switching states Lamp test After the ignition has been switched on, a lamp test is performed. Risk of accident from 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 187: Display - Setting The Brightness
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.7 Display – setting the brightness Brightness of the displays The brightness of the displays is regulated automatically by the CCS , depending on the ambient brightness. You can set a minimum brightness that may be reached.
Page 188 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab You can cancel the entry at any time using the (1) or (2) buttons. The settings are then reset. 4 - 12 3 302 709 en Operating manual GMK5150L...
Page 189: Starting The Engine
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.8 Starting the engine This section describes only how to start the engine from the driver's cab. à You can also start the engine from the outrigger control units; p.
Page 190 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab This section pertains 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. The starter fuel sprayed into the intake manifold can ignite.
Page 191: Checks After Starting The Engine
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.9 Checks after starting the engine Risk of damage to the engine Observe the symbols and messages in the display area of the main menu and in the on-board computer.
Page 192 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab • Check the display (1) in the Start menu or in the Driving menu. If the symbol is blue, then the steering angle is not correct based on the 1st and 2nd axle lines.
Page 193: Setting The Idling Speed
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.10 Setting the 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 194: Switch Off The Engine
Starting the engine for driving / switching it off 4.2 Switch off the engine Switch off the engine 4.2.1 At the ignition lock and with 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 195: Using The Emergency Stop Switches
Starting the engine for driving / switching it off 4.2 Switch off the engine 4.2.2 Using the emergency stop switches Emergency stop switch Three emergency stop switches are provided for emergency use: 1 On the carrier 2 On the hand-held control unit 3 In the crane cab •...
Page 196: 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 – symbol (1) red – in the start menu display à...
Page 197: 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 operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1. For on-road driving without a dolly –...
Page 198 Driving 5.1 Before driving 3. On the outriggers – All outrigger beams must be fully retracted and secured to prevent à extension; p. 12 - 46. à – The outrigger pads are in the driving position p. 12 - 53. à...
Page 199 Driving 5.1 Before driving à 8. All railings must be folded in; p. 12 - 149. 9. Check the tyres: à – Tyre pressure when tyres are cold in on-road mode; p. 1 - 18. à Maintenance manual . – Other checks; 10.
Page 200 Driving 5.1 Before driving 14. 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 201 Driving 5.1 Before driving à 20. Adjust the steering column; p. 5 - 15. à 21. Adjust the mirrors; p. 5 - 7. à 22. Set the tachograph, insert the diagram sheet; p. 5 - 18. à Checks after starting the 23.
Page 202 Driving 5.1 Before driving 25. Check the fluid supply: à – Fuel tank , p. 4 - 5, à – AdBlue tank , p. 4 - 7. à 26. Check the compressed-air system and the brakes; p. 5 - 10. 27.
Page 203: 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 204 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 205 Driving 5.1 Before driving Warning plates for Depending on the vehicle width and version, fold-up warning plates are vehicle width fitted below the driver's cab. The warning plates (1) must be folded down to indicate the vehicle width during on-road driving.
Page 206 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 about 8 bar (116 psi). If the supply pressure is too low, such as after repairs, you can build it up as follows.
Page 207 Driving 5.1 Before driving Parking brake Check the function of the parking brake. • Activate the service brake. Risk of accidents by truck crane moving unintentionally Always apply the service brake before releasing the parking brake. This prevents the truck crane rolling in an uncontrolled manner when the parking brake is released.
Page 208 Driving 5.1 Before driving Third brake light If a third brake light is present, then you must check to ensure it is correctly connected. One brake light (1) is at the rear of carrier. If a storage box is present, then there is another brake light (2) there.
Page 209: Adjusting The Seat And The Steering Column
Driving 5.1 Before driving 5.1.3 Adjusting the seat and the steering column Adjusting the The seat height and lumbar support are adjusted pneumatically. You can driver's seat only make these adjustments when: – the switch (1) on the driver's seat is switched off (not pressed in), –...
Page 210 Driving 5.1 Before driving Settings for body shape 1 Lower lumbar area support 2 Upper lumbar area support 3 Lateral support The settings are made pneumatically. The following applies to all buttons: Empty the air cushion: Press – Fill the air cushion: Press + Adjusting the The passenger's seat is adjusted mechanically.
Page 211 Driving 5.1 Before driving Adjusting the The steering column is unlocked pneumatically. steering column 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 can be unlocked only when sufficient supply pressure à...
Page 212: 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 the menus. Symbol green: Suspension is switched on Symbol red:...
Page 213 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 214: 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 215 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 216 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 217 Driving 5.1 Before driving Display If no malfunction has occurred, 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 218 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 automatically switches to the symbol for driver 1 driving time. If there are two diagram sheets inserted, the tachograph automatically switches to stand-by time for two-drivers operation.
Page 219: 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 – expressed as a deviation from UTC time.
Page 220: 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 221: Operating The Transmission
Driving 5.2 Operating the transmission Operating the transmission The transmission automatically controls all gear changes. However, 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 N.
Page 222: 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 223: 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 224 Driving 5.2 Operating the transmission For reversing The reversing camera and the reversing lamp are switched on. The display (1) shows the area behind the truck crane. When you exit the transmission mode R, the reversing lamp and camera are switched off and the display (1) shows the CCS menu.
Page 225: 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 226: 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 227: 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 228 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 229: 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 230: On The Roller Type Dynamometer
Driving 5.2 Operating the transmission 5.2.9 On the roller type dynamometer Danger of unexpected 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 231: Driving The Truck Crane And Switching It Off
Driving 5.3 Driving the truck crane and switching it off Driving the truck crane and switching it off Risk of accidents because the truck crane cannot be steered. Never switch off the ignition or remove the ignition key while the truck crane is moving This precaution prevents the steering locking and consequent loss of control of the moving truck crane.
Page 232 Driving 5.3 Driving the truck crane and switching it off • Steering Always pay attention to all the indicator lamps and all information in this and subsequent sections. Risk of accident due to mobile crane that cannot be steered and leaking oil If a warning message occurs, be sure to follow the instructions in this sec- tion and take all the measures specified.
Page 233 Driving 5.3 Driving the truck crane and switching it off • Monitoring Also pay attention to the monitoring elements. elements Tachometer 1 Green: Economic consumption 2 Yellow: Engine brake active 3 Red: Engine speed too high – danger; à Checks when driving downhill , p. 5 - 42 Fuel level display à...
Page 234: Cruise Control
Driving 5.3 Driving the truck crane and switching it off 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 235 Driving 5.3 Driving the truck crane and switching it off Switching off • Press the button (1) once. The cruise control is now switched off. The symbol (2) goes out in the Driving display. Cruise control is also switched off, –...
Page 236: Temposet
Driving 5.3 Driving the truck crane and switching it off 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 237: Driving Downhill
Driving 5.3 Driving the truck crane and switching it off 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.
Page 238 Driving 5.3 Driving the truck crane and switching it off 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 239 Driving 5.3 Driving the truck crane and switching it off 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 240: Driving Uphill
Driving 5.3 Driving the truck crane and switching it off 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.
Page 241: Overriding Torque Reduction
Driving 5.3 Driving the truck crane and switching it off 5.3.6 Overriding torque reduction If the AdBlue tank is empty, 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 242: Switching The Truck Crane Off
Driving 5.3 Driving the truck crane and switching it off 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.
Page 243 Driving 5.3 Driving the truck crane and switching it off Additional chocks can be transported in the storage compartment on the turntable or at the rear of the truck crane. • When stationary Switch off all current consumers, for example, auxiliary heaters. for more than •...
Page 244: Fold-Up Berth
Driving 5.3 Driving the truck crane and switching it off 5.3.8 Fold-up berth The berth must always be folded up and secured 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 245: 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 246: Transfer Case - Switching The Off-Road Gear On/Off
If the error symbol is displayed, contact Manitowoc Crane Care Neutral position The transfer case is put into neutral position when the towing mode is à...
Page 247: Longitudinal And Transverse Differential Locks
Driving 5.4 Off-road driving 5.4.2 Longitudinal and transverse differential locks – The longitudinal differential locks prevent individual axle lines spinning when driving on a slippery surface. With the 10 x 8 x 10 drive, the 3rd axle line drive is switched on and off. –...
Page 248 – first symbol (2) – yellow, then symbol (3) – green, differential locks off. If symbol (3) is not green then drive back and forth slowly. If the error symbol is displayed, contact Manitowoc Crane Care 5 - 52 3 302 709 en Operating manual GMK5150L...
Page 249: Operating The Level Adjustment System
– Set the on-road driving level – Pre-select the suspension struts and change the vehicle level. If the symbol (3) is shown for an error during a level adjustment, refer to Manitowoc Crane Care Operating manual 3 302 709 en 5 - 53 GMK5150L...
Page 250 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 251 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 252 Driving 5.4 Off-road driving Viewing the The inclination indicator shows the current alignment. current inclination Switching over the measuring range The measuring range is automatically switched between 1° and 5°. (A) – When the truck crane is level the marking (1) is in the middle. (B) –...
Page 253: Freeing Truck Crane Stuck In Terrain
Driving 5.4 Off-road driving 5.4.4 Freeing truck crane stuck in terrain 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 254 Driving 5.4 Off-road driving • Towing free Fasten a steel rope to the front towbar coupling. forwards Risk of damage to the chassis Only tow the truck crane free while observing the procedure given for the pulling direction. Jerking the truck crane or pulling it at an angle can cause damage to the chassis.
Page 255: Separate Steering
Driving 5.5 Separate steering Separate steering There are two steering modes with separate steering. – Driving around corners: When separate steering is switched on, the steering angle is larger than for normal steering mode – the turning circle is smaller. –...
Page 256: Switching To Separate Steering
Driving around corners . à If the error symbol is displayed, contact p. 8 - 24. Manitowoc Crane Care When separate steering is switched on, the speed is limited to about 20 m/h (12 mph). 5 - 60...
Page 257 Driving 5.5 Separate steering Sterring with separate steering – automatic • Steer the 1st and 2nd axle line with the steering wheel. The electronics will register the steering angle on the 1st and 2nd axle lines and automatically steer the wheels of the 3rd and 5th axle lines. (A) –...
Page 258 Driving 5.5 Separate steering (A) – For driving around corners • Steer the 3rd and 5th axle lines in the oppo- site direction to the 1st and 2nd axle lines. (B) – For crab travel mode • Steer the 3rd and 5th axle line in the same direction as the 1st and 2nd axle line.
Page 259: Switching To Normal Steering Mode
– the current wheel position is dis- played. • Select and confirm the symbol (1) – symbol (2) is displayed. à If the error symbol is displayed, contact p. 8 - 24. Manitowoc Crane Care Operating manual 3 302 709 en 5 - 63 GMK5150L...
Page 260: Switching Units Of Measure
Driving 5.5 Separate steering 5.5.3 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 selection.
Page 261: 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. The heating output is only provided when the engine is running. Heating You must set the blower and the temperature. Setting the fan Setting the fan You can regulate the air volume with the switch (1) for:...
Page 262 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 263 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) – Ventilating – Turn the switches to the positions shown. – If necessary, open the air vents for the side and centre.
Page 264: 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. Notes 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 265 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 on – the lamp (4) lights up. • Turn the switch (3) as far as it will go, to Cold . •...
Page 266: Auxiliary Water Heating System
Driving 5.6 Heating and air-conditioning system 5.6.3 Auxiliary water heating system 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. Further information on the operation of the auxiliary water heating system is provided at the address Webasto.com .
Page 267 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 (1) pushed in at the top. • Switch (2) to the required fan level Recirculated air .
Page 268 Driving 5.6 Heating and air-conditioning system This section describes how to switch on manually. The auxiliary heater can à Storing the heating start , p. 5 - 74. also be switched on automatically; à • Switch the ignition on , p. 4 - 9. Switch on the ignition;...
Page 269 Driving 5.6 Heating and air-conditioning system Always switch the auxiliary heater off if you switch off the truck crane whilst the battery master switch is switched on. In this way, you prevent the auxil- iary heater from restarting and the batteries from running down after the engine has cooled down.
Page 270 Driving 5.6 Heating and air-conditioning system • At the flashing display, set the minutes and confirm the selection. The time and day of the week have now been set. Storing the Heating is started automatically on schedule only if the time and the day of à...
Page 271 Driving 5.6 Heating and air-conditioning system • Select and confirm the desired heating mode. – economical (1) – comfortable (2) – quick (3) • Select and confirm the desired temperature. After the desired temperature has been input, the set values are saved and shown in the display: –...
Page 272: Auxiliary Air Heater
Driving 5.6 Heating and air-conditioning system 5.6.4 Auxiliary air heater You can use the auxiliary heating to preheat the driver's cab or provide additional heating. The auxiliary heater is supplied from the fuel tank. The batteries will be drained if you operate the auxiliary heater with the engine switched off.
Page 273 Driving 5.6 Heating and air-conditioning system This section describes how to switch on manually. The auxiliary heater can à Auxiliary water heating system , also be switched on automatically; p. 5 - 70. à • Switch the ignition on , p. 4 - 9. Switch on the ignition;...
Page 274 Driving 5.6 Heating and air-conditioning system Setting the day Always set the current time and current day of the week. These settings are and time required for the correct activation point of the automatic heating start. If the electric power supply is interrupted, you have to reset the time and day of the week.
Page 275 Driving 5.6 Heating and air-conditioning system • Use button (1) or (2) in program column (3) to select storage location 1, 2 or 3 and confirm with button (4). • Use button (1) or (2) in program column (3) to select a day of the week and confirm with button (4).
Page 276: Radio
Driving 5.7 Radio If you have set a preselection time (departure time) of e. g. 12.00 and a heat- ing period of 30 minutes, the auxiliary heater starts at 11.30, for example. Preselection times Delete • To delete the preselection times, repeat the steps for setting preselection à...
Page 277: Towing A Trailer
Driving 5.8 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 rolling away.
Page 278 Driving 5.8 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 5.8 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 5.8 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 moving when you remove the brake hose. •...
Page 281 Driving 5.8 Towing a trailer Risk of injury when closing the towbar coupling by hand 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 5.8 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). points Manitowoc Crane Group Germany GmbH out that if the truck crane is driven with axle loads greater than 12 t (26,500 lbs),the brake system may overheat and the braking deceleration required by the EU partial type-approval cannot be met.
Page 284: How To Use The Tables
This section only shows some standard driving modes. For further information on additional or individual driving modes, please contact Manitowoc Crane Care The tables consist of two parts: – The driving mode of your truck crane is specified in the top part, next to Equipment.
Page 285 Driving modes and rigging for on-road driving 6.1 Driving modes 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs) Tyres Also observe the effects on the axle loads when towing a trailer; à 385/95 R25 p. 5 - 81. Driving mode ✔...
Page 286 Driving modes and rigging for on-road driving 6.1 Driving modes Tyres Also observe the effects on the axle loads when towing a trailer; à 445/95 R25 p. 5 - 81. Driving mode ✔ Drive 10 x 6 x 10 Drive 10 x 8 x 10 ✔...
Page 287 Driving modes and rigging for on-road driving 6.1 Driving modes Tyres Also observe the effects on the axle loads when towing a trailer; à 525/80 R25 p. 5 - 81. Driving mode ✔ Drive 10 x 6 x 10 Drive 10 x 8 x 10 ✔...
Page 288: 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 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 GMK5150L 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: Raising/Lowering The 3Rd Axle Line For Dolly Operation
Driving modes and rigging for on-road driving 6.3 Rigging work for driving with a dolly 6.3.4 Raising/lowering the 3rd axle line for dolly operation • Open the Suspension/level adjustment (1) menu. Lifting • Use the level adjustment system to lower the truck crane to its lowest position;...
Page 298 Driving modes and rigging for on-road driving 6.3 Rigging work for driving with a dolly Blank page 6 - 16 3 302 709 en Operating manual GMK5150L...
Page 299: Rigging The Main Boom
Without these factory-installed pulling devices, the main boom may be removed by only. Manitowoc Crane Care Additional equip- In addition to the pulling devices, you also need the following accessories: ment required –...
Page 300: 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 operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified there! Prerequisites –...
Page 301 Driving modes and rigging for on-road driving 6.4 Rigging the main boom 4. Place the main boom on the boom rest. à 5. Sling the main boom to an auxiliary crane; p. 6 - 26. à 6. Switch on the derricking cylinder pressure relief; p.
Page 302 Driving modes and rigging for on-road driving 6.4 Rigging the main boom 9. Raise the main boom from the turntable. 10. Put the main boom on the separate vehicle and secure for transport; à p. 6 - 35. à 11. Secure the derricking cylinder with a tightening belt; p.
Page 303: Checklist: Mounting The Main Boom
Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.2 CHECKLIST: Mounting the main boom This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified there! Prerequisites The truck crane is supported with at least an outrigger span of 8.030 x 2.50 m (26.3 x 8.2 ft).
Page 304 Driving modes and rigging for on-road driving 6.4 Rigging the main boom 4. Lift the main boom into the turntable and align the connecting points; à p. 6 - 36. 5. On the boom pivot pin – Push in the pivot pin –...
Page 305 Driving modes and rigging for on-road driving 6.4 Rigging the main boom à 10. Establish the hydraulic/electric connection; p. 6 - 24. 11. Remove the derricking cylinder support from the counterweight platform. 12. Place the main boom on the boom rest. à...
Page 306: Disconnecting/Connecting Hydraulics/Electrical
Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.3 Disconnecting/connecting hydraulics/electrical 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. This prevents malfunctions in the electronics and corresponding error messages in the subsequent crane operation.
Page 307 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Establish • Remove the bridging plug (3). • Connect the plug (4) to the socket. • Connect all hoses (1) to the connections (2). The assignment is given by the size and col- our designations.
Page 308: Derricking Cylinder Support
Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.4 Derricking cylinder support Before removal Before retracting the head pin, the derricking cylinder support must be erected. • Place the derricking cylinder support (1) between the holders (2). •...
Page 309 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Attach lifting gear • If the installation is correct, the load-bearing equipment (2) of both brackets point to each other. • Lock both brackets in the wide position. Secure the pins (1) using the retaining pins.
Page 310 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Removing the sling gear • Remove the pin (2) and pull the bracket (5) out of the slinging point (4) • Secure the bracket with the pin (2) and the retaining pin.
Page 311: Switching The Pressure Relief On/Off
Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.6 Switching the pressure relief on/off Pressure relief prevents the derricking cylinder from extending when the engine runs, after the main boom has been removed. When removing • Switch the pressure relief on before pulling the derricking cylinder head axle.
Page 312: Retracting/Fitting The Derricking Cylinder Head Pin
Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.7 Retracting/fitting the derricking cylinder head pin Operating the A lifting device is needed in order to relieve and level the derricking cylinder. lifting device Danger from using unsuitable lifting device Have the lifting device serviced in time before the maintenance interval specified on the label expires •...
Page 313 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Risk of accident from falling derricking cylinder! Always take the load off of the derricking cylinder using the lifting device before retracting the head pin. By doing this, you prevent the derricking cylinder from falling down, injuring people or being damaged while retracting the head pin.
Page 314: Extending/Retracting The Boom Pivot Pin
Driving modes and rigging for on-road driving 6.4 Rigging the main boom Risk of damage to the bearings in the derricking cylinder head Make sure that the bearings in the derricking cylinder are aligned with the head pin before fitting the head pin. This prevents the head pin from damaging the bearing.
Page 315 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Switching over the hydraulic circuit • Switch over valves – lever (4) vertical. Releasing the pivot pin • Remove the pins (1) from the connecting points (2) and insert them into the connect- ing points (3).
Page 316 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Pushing the After pushing in, you must secure the pivot pins and switch the hydraulic pivot pin in circuit over. Risk of damage to the main boom Before pushing in, the bearing points on the turntable must be aligned with the boom pivot pin.
Page 317: 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 à size and has sufficient lifting capacity; p. 1 - 10. Risk of damage to the main boom Always place the main boom onto a suitable packing.
Page 318: Aligning The Connecting Points
Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.11 Aligning the connecting points Risk of damage to the turntable and the connection lines Make sure that the connection lines are located within the turntable and that the main boom does not swing when you raise it for insertion into the turntable.
Page 319: Inspections After Main Boom Mounting
Driving modes and rigging for on-road driving 6.4 Rigging the main boom 6.4.12 Inspections after main boom mounting • Check to see if the pressure relief is switched off and is secured with the à lock; p. 6 - 29. •...
Page 320 Driving modes and rigging for on-road driving 6.4 Rigging the main boom Blank page 6 - 38 3 302 709 en Operating manual GMK5150L...
Page 321: Rigging The Auxiliary Hoist
Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist Rigging the auxiliary hoist You will require the following equipment with a sufficient load bearing capacity: – An auxiliary crane – Suitable lifting gear and guide ropes, – A separate vehicle. à...
Page 322: Checklist: Installing The Auxiliary Hoist
Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist 6.5.2 CHECKLIST: Installing the auxiliary hoist – The superstructure is slewed to the front. – The main boom is resting in the boom rest. 1. Attach the auxiliary hoist at the centre of gravity and remove the pins à...
Page 323: Checklist: Removing The Auxiliary Hoist
Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist 6.5.3 CHECKLIST: Removing the auxiliary hoist – The main boom must be resting in the boom rest. – The hoist rope is unreeved. 1. Wind on the auxiliary hoist rope, using the rigging aid if necessary; à...
Page 324: Making/Breaking The Connection Between The Auxiliary Hoist And The Turntable
Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist 6.5.4 Making/breaking the connection between the auxiliary hoist and the turntable Making the connection • Suspend the auxiliary hoise in the connect- ing points (3) at the turntable. •...
Page 325: Establishing/Disconnecting The Hydraulic Connections
Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist 6.5.5 Establishing/disconnecting the hydraulic connections Making the connection The assignment is given by the size and colour designations. • Connect the hoses (1) to the connections (2). Undoing the connection •...
Page 326: Disconnecting/Establishing The Electrical Connection
Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist 6.5.6 Disconnecting/establishing the electrical connection Making the connection • Remove the plug (2) from the dummy socket (3) and plug it into the socket (1). • Close the dummy socket (3). Undoing the connection •...
Page 327: Making/Breaking The Connection To The Central Lubrication
Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist 6.5.7 Making/breaking the connection to the central lubrication Making the connection • Connect the hose (1) to the connection (2) Undoing the connection • Remove the hose (1) from the connec- tion (2).
Page 328: Transporting The Auxiliary Hoist
Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist 6.5.8 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 - 21. •...
Page 329: Check That The Auxiliary Hoist Is Functioning Properly
Check the function of the slewing indicator when applying the hoist rope. • You should feel a pulse on the slewing indicator (1) when the auxiliary hoist is rotating. • If no pulse is present, contact Manitowoc Crane Care Operating manual 3 302 709 en 6 - 47 GMK5150L...
Page 330: Rigging Aid For The Hoist Rope
Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist 6.5.10 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 331 Driving modes and rigging for on-road driving 6.5 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 332 Driving modes and rigging for on-road driving 6.5 Rigging the auxiliary hoist Blank page 6 - 50 3 302 709 en Operating manual GMK5150L...
Page 333: Installing/Removing The Outrigger Beams
Driving modes and rigging for on-road driving 6.6 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 334: Checklist: Removing The Outrigger Beams
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.1 CHECKLIST: Removing the outrigger beams This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! à...
Page 335 Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams à 6. Disconnect the connection to the support box; p. 6 - 64. 7. Sling the outrigger beam and pull it out of the outrigger box until it à...
Page 336: Checklist: Installing The Outrigger Beams
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.2 CHECKLIST: Installing the outrigger beams This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! à...
Page 337 Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams à 6. Screw in the spacers; p. 6 - 62. à 7. If necessary, put supporting pads into position; p. 6 - 58. 8. Mount all necessary outrigger beams in the same way in accordance with this checklist.
Page 338: Centre Of Gravity Data
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.3 Centre of gravity data The information in this section relates to a fully retracted outrigger beam package. The centre of gravity is defined by the distance (A). Outrigger pads Without 840 mm (33.10 in)
Page 339: Preparations - On The Truck Crane
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.5 Preparations – on the truck crane Prerequisites The following requirements must be met before mounting/removing the outrigger beams: – All rigging work which involves slewing the superstructure has been completed.
Page 340: Removing/Attaching Outrigger Pads
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.6 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 341 Driving modes and rigging for on-road driving 6.6 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 342: Disconnecting/Establishing Hydraulic Connection
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.7 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. Undoing the connection Always disconnect all connections (4).
Page 343: Disconnecting/Establishing The Electrical Connection
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.8 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 344: Unscrewing/Screwing In The Spacers
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.9 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 beam on the front right hand side.
Page 345 Driving modes and rigging for on-road driving 6.6 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 outrigger beam (4) at the top.
Page 346: Disconnecting/Establishing The Connections To The Supporting Box
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.10 Disconnecting/establishing the connections to the supporting The illustrations show the connecting point for the front right outrigger beam as an example. (A) – Disconnecting the connection • Remove the nut (3).
Page 347 Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams • Fasten the lifting gear (1) and a chain hoist. • Pull the outrigger beam out so far that the à Centre centre of gravity (2) is accessible; of gravity data , p.
Page 348 Driving modes and rigging for on-road driving 6.6 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 349 Driving modes and rigging for on-road driving 6.6 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 350: Transporting The Outrigger Beams
Driving modes and rigging for on-road driving 6.6 Installing/removing the outrigger beams 6.6.12 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 351: Transport
Transport 7.1 Transport with transport vehicle Transport Transport should be carried out only by qualified heavy transport compa- nies whose personnel are well-acquainted with loads of these dimensions and weights. Transport with transport vehicle Risk of accidents due to improper transport! Assign transportation to only qualified companies and ensure that the regulations applicable in the country in which you are working are adhered to.
Page 352: Checklist: Checks Before Transport
Transport 7.1 Transport with transport vehicle 7.1.1 CHECKLIST: Checks before transport This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1. For on-road driving without a dolly –...
Page 353 Transport 7.1 Transport with transport vehicle 4. The anemometer and air traffic control light must be removed; à Anemometer and air traffic control light , p. 12 - 145. à 5. All railings must be folded in; p. 12 - 149. à...
Page 354: Drive The Truck Crane On To The Transport Vehicle
Transport 7.1 Transport with transport vehicle 9. 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. All additional parts which may be transported must be secured against falling down.
Page 355 Transport 7.1 Transport with transport vehicle Driving on • Drive the truck crane onto the trailer. Apply the parking brake immediately, and switch the engine off. • Close all the doors. Lashing Risk of accidents due to falling parts Use only suitable lifting gear with sufficient load bearing capacity and use only the slinging points provided.
Page 356: Transport By Ship
Transport 7.2 Transport by ship Transport by ship Risk of accidents due to falling parts Use only suitable lifting gear with sufficient load bearing capacity and use only the slinging points provided. • Secure the truck crane with the chocks (1). •...
Page 357: Malfunctions In Driving Mode
Malfunctions in driving mode 8.1 Emergency stop switch Malfunctions in driving mode Emergency stop switch Three emergency stop switches are provided for emergency use: 1 On the carrier 2 On the hand-held control unit 3 In the crane cab • Press an emergency stop switch (1), (2) or (3).
Page 358: 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 the truck crane , p. 8 - 29.
Page 359: 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 repair shop. The coolant temperature is too high – the motor output is automatically reduced.
Page 360: 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 361: Warning And Error Messages
• Always note down the number of the program version and the serial number after a malfunction occurs before notifying Manitowoc Crane Care The crane type (1) and the serial number (2) are shown in the start menu. à The program version is displayed in the crane cab;...
Page 362 If oil has leaked out • Warn any vehicles on the road behind you. • Do not continue driving. Contact Manitowoc Crane Care If no oil has leaked out à • Maintenance manual . Check the hydraulic oil level;...
Page 363 Whether it is possible to continue driving must be decided based on the current situation. Contact Manitowoc Crane Care If necessary, the 3rd and 4th axle lines can be steered into the straight run- ning position with emergency operation to make it possible to drive to the à...
Page 364 Malfunctions in driving mode 8.3 Warning and error messages AdBlue system • Also check the control elements for the Adblue system; à Faults on the Adblue system , p. 8 - 21. 8 - 8 3 302 709 en Operating manual GMK5150L...
Page 365: Warning And Malfunction Messages On The On-Board Computer Display
Malfunctions in driving mode 8.3 Warning and error messages 8.3.2 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 366 • Add oil if necessary. If the error message is still displayed, please 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 lights up or the warning buzzer sounds.
Page 367 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 repair shop. The clutch has a malfunction – driving can continue with restrictions.
Page 368 Malfunctions in driving mode 8.3 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 369: Warning Messages On The Ccs Display
Malfunctions in driving mode 8.3 Warning and error messages 8.3.3 Warning messages on the CCS display A warning message indicates that certain values do not correspond to a target value. If CCS detects a warning or a fault then in the display area (1) a symbol is displayed.
Page 370 Malfunctions in driving mode 8.3 Warning and error messages AdBlue tank level too low à Refill the AdBlue tank; p. 4 - 7. Replace hydraulic oil filter Replace the corresponding hydraulic oil filter as soon as possible; à Maintenance manual . Hydraulic oil too hot The hydraulic oil temperature is higher than 80 °C (176 °F).
Page 371 Malfunctions in driving mode 8.3 Warning and error messages Refuelling The fuel tank is filled only to a level of about 5%. à • Refuel before the fuel is used up; p. 4 - 5. If the fuel tank is almost empty, air will be sucked in and you will have to à...
Page 372 à p. 8 - 17. • If necessary, note the error messages and contact Manitowoc Crane Care CAN bus malfunction • Switch off the ignition and wait about 15 seconds, then switch it on again. If the malfunction is still present, contact...
Page 373: Error Messages On The Ccs Display
Malfunctions in driving mode 8.3 Warning and error messages 8.3.4 Error messages on the CCS display Risk of accidents The crane control may only be repaired by qualified personnel. • If an error message occurs, stop while taking the traffic situation into con- à...
Page 374 1 Engine 2 Transmission • Always note the error code before contacting Manitowoc Crane Care Exiting the menu You can exit the Engine errors menu at any time. • Press the button (1) once. The next highest menu is opened.
Page 375: Troubleshooting
Malfunctions in driving mode 8.4 Troubleshooting Troubleshooting 8.4.1 Malfunctions on the engine à Separate engine operating instructions, pro- In addition to this information; vided by the manufacturer . Malfunction Cause Solution Engine does not start – Battery master switch is Switch on the battery master à...
Page 376 – the symbol is displayed. The symbol is displayed, Due to a malfunction, the Inform Manitowoc Crane Care the engine output falls power is continuously continuously (coolant reduced. The engine is not temperature is too high)
Page 377: Faults On The Adblue System
– Flashing AdBlue tank empty – AdBlue tank sensor faulty Have the exhaust system – Error on the AdBlue dosing checked by Manitowoc – Light up unit , an authorised Crane Care – AdBlue lines blocked GROVE retailer or an –...
Page 378: Differential Lock Malfunctions
Fuse has blown Replace blown fuses; à p. 8 - 50 Error symbol is displayed CCS malfunction Read out error messages à p. 8 - 17) and notify Manitowoc Crane Care 8 - 22 3 302 709 en Operating manual GMK5150L...
Page 379: Malfunctions In The Transmission
Malfunctions in driving mode 8.4 Troubleshooting 8.4.5 Malfunctions in the transmission Malfunction Cause Solution Transmission only shifts up Transmission oil too hot Switch to the neutral posi- to 2nd gear – the symbol is tion and wait until the displayed transmission oil has cooled down Transmission oil colder...
Page 380: Malfunctions Of The Steering
Malfunctions in driving mode 8.4 Troubleshooting 8.4.6 Malfunctions of the steering Malfunction Cause Solution Steering wheel hard to Lamps can light up Check the hydraulic oil à Maintenance turn, grating noises when Oil level in the hydraulic oil level; manual . steering tank too low Then drive at low speed to...
Page 381: Malfunctions Of The Service Brake
Malfunctions in driving mode 8.4 Troubleshooting 8.4.7 Malfunctions of the service brake Malfunction Cause Solution Lights up while The air pressure in one of The vehicle can be driven driving or does not the two circuits has fallen slowly to the next repair shop go out after the below 5.5 bar (80 psi) engine is started...
Page 382: Malfunctions Of The Level Adjustment System
Malfunctions in driving mode 8.4 Troubleshooting 8.4.9 Malfunctions of the level adjustment system Malfunction Cause Solution à Switching the suspension on , Level adjustment system not Suspension is switched off working p. 5 - 17 Control unit fuse blown Replace blown fuses; à...
Page 383: Emergency Operation And Breakdown Assistance
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Emergency operation and breakdown assistance 8.5.1 Starting the truck crane externally • Start the engine of the auxiliary vehicle. • (A) – Connect the cable (1) to the power supply (24 V) of the auxiliary vehicle. •...
Page 384: Battery Charger
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.2 Battery charger Prerequisites – The engine must not be running and must be secured against unauthorised use. – An external 230 V mains power supply must be available at the location. –...
Page 385: Towing The Truck Crane
Tow the truck crane at a maximum speed of 7 km/h (4 mph) and for a maximum distance of 100 m (330 ft). For longer distances, additional measures must be taken, refer to Manitowoc Crane Care Compressed-air supply If the engine fails, the truck crane must be supplied with compressed air by the tractor-vehicle so that the brake system is still operable.
Page 386 Malfunctions in driving mode 8.5 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 387 If the lamp (1) does not go out, there is a malfunction on the parking brake system. Contact Manitowoc Crane Care Risk of accidents due to faulty brakes If the service brake system has been damaged, you may only tow...
Page 388 • If you need to tow the truck crane further than 100 m (330 ft) contact Manitowoc Crane Care Risk of accidents and damage when towing the truck crane long distances Tow the truck crane at a maximum speed of 7 km/h (4 mph) and for a max- imum distance of 100 m (330 ft).
Page 389: Wheel Change
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.4 Wheel change • If a puncture occurs while driving, stop the truck crane, taking the follow- ing traffic into account, and secure the truck crane as outlined in the appli- cable legal stipulations of the country in which you are working.
Page 390 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance à • Removing a Switch off the suspension; p. 5 - 17. 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 391 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Third brake light If there is a third brake light, then you have to remove it before removing the wheel from the spare wheel holder. Before driving on the road, the brake light must be reattached.
Page 392 Check the wheel rim, tyres, lug nuts and wheel studs for damage before mounting the spare wheel. Damaged parts may not be mounted Mount only the original wheel supplied by Manitowoc Crane Group Germany or an approved wheel of the same size and load bearing capacity! GmbH •...
Page 393: Inflating The Tyres Yourself
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.5 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. A tyre inflator connection set to a pressure of 10 bar (145 psi) is provided for this purpose.
Page 394 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Inflating the tyres The maximum operation pressure of the compressed air system of 10 bar (145 psi) can only be reached with the engine running. à • Start the engine; p.
Page 395: Emergency Operation, Steering 3Rd And 4Th Axle Lines
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.6 Emergency operation, steering 3rd and 4th axle lines If there is a warning message in the steering system – lamp (1) lights and symbol (2) is red – the steering of the defective axle line will be locked. This axle line can then no longer be steered from the driver's cab or from the crane cab.
Page 396 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Performing If the current situation allows it, you can slightly lift the mobile crane with emergency the support to relieve the axle line. operation For the operation, you must – Take out two fuses. –...
Page 397 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Risk of crushing due to turning wheels Ensure that there are no persons near the wheels being steered before steering an axle line with emergency operation. Steering of the 3rd axle line The valves are labelled.
Page 398 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Check valves – switch off continuous operation – For the 3rd axle line • Always switch off the continuous operation for all valves (1). – For the 4th axle line •...
Page 399: Tilting/Lowering The Driver's Cab
Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab Tilting/lowering the driver's cab To tilt the driver's cab (e.g. for maintenance work), the main boom must be raised and the hoisting gear moved. This assumes that the engine can be started. If the engine cannot be started, you must use the hydraulic emergency à...
Page 400 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab 8.6.2 Tilting and lowering the driver's cab Operating the The driver's cab is tilted and lowered using a hand pump. The lever for the hand pump hand pump is below the seats or in the tool box. •...
Page 401 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab • Tilting the Remove all loose objects from the driver's cab. Close the doors. driver's cab Risk of accidents from loose objects and doors swinging open Remove all loose objects (e.g. bottles) from the driver's cab so that they do not fall out when the cab is tilted.
Page 402 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab • Continue to pump until the driver's cab tilts no further. • Secure the driver's cab – fold out the fall-back guard strut (1). Risk of accidents due to the driver's cab tilting back. You may only stand under the tilted driver's cab if the fall-back guard strut is folded out.
Page 403 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab • Remove the lever (1) and stow it away safely. à • Front flap , p. 3 - 73. Close the front flap; Operating manual 3 302 709 en 8 - 47 GMK5150L...
Page 404 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab Blank page 8 - 48 3 302 709 en Operating manual GMK5150L...
Page 405 Notify if a fuse with the same amperage blows again Manitowoc Crane Care when the ignition is switched on. Risk of fire Never repair a blown fuse with other electrically conductive materials.
Page 406 Malfunctions in driving mode 8.7 Fuses on the carrier 8.7.1 Fuses in the driver's cab The driver's cab contains fuse groups F1 to F6. • Remove the cover (1). The following tables show the designations of the individual fuses, including their amperage and functions.
Page 407 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function F2/1 Control unit UB 1 IOL 31 F2/2 Control unit UB 1 IOL 31 F2/3 Control unit UB 2 IOL 31 F2/4 Control unit UB 2 IOL 31 Control unit UB 1 IOL 32 F2/5 Electronic steering system...
Page 408 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function F4/1 Cab lighting F4/2 Dual tank switchover CCS display F4/3 F4/4 Unassigned F4/5 Unassigned F4/6 Unassigned F4/7 Unassigned F4/8 Unassigned Designation Amperage (A) Function F5/1 Auxiliary heater Control unit UE CCM 11 F5/2 Control unit UE 2 IOL 31/32/33...
Page 409 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function Engine emergency stop switch F6/1 Tachograph, instrument panel Control unit CCM 11 F6/2 Control unit IOL 31/32/33 Display CCS F6/3 Reverse camera Radio F6/4 Air intake inhibitor F6/5 Gearbox control F6/6...
Page 410 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function F8/1 Central lubrication F8/2 Windscreen wiper F8/3 Steering coupling F8/4 ABS trailer F8/5 Horn F8/6 Unassigned Operating the mirror adjustment F8/7 Window winder F8/8 Unassigned Designation Amperage (A) Function Temperature gauge F9/1...
Page 411 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function Turn signal indicators F10/1 Light switch F10/2 Rotating beacon carrier/superstructure Parking light F10/3 Side marker lights Side marker lights, front F10/4 Instrument lighting Brake lights F10/5 Trailer brake lights Light switch F10/6 Warning blinkers...
Page 412 Malfunctions in driving mode 8.7 Fuses on the carrier 8.7.2 Fuses in the battery box Fuses F7 to F16 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 413: Operating Elements For Crane Operation
Operating elements for crane operation 9.1 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 414: Exterior Of The Truck Crane
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.1 Exterior of the truck crane 9 - 2 Operating manual GMK5150L...
Page 415 Operating elements for crane operation 9.1 Overview of the operating elements à 1 – Camera on main boom p. 12 - 152 à – Camera on the hoists p. 12 - 155 à – Camera on the driver's cab p. 12 - 155 à...
Page 416 Operating elements for crane operation 9.1 Overview of the operating elements 9 - 4 Operating manual GMK5150L...
Page 417 Operating elements for crane operation 9.1 Overview of the operating elements 18 Outriggers: à – Control units p. 9 - 85 à – Control units for raising the axles p. 9 - 85 à – Emergency stop switch p. 14 - 1 19 Slinging points à...
Page 418: Crane Cab
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.2 Crane cab 9 - 6 Operating manual GMK5150L...
Page 419 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Side panel p. 9 - 8 2 Sun visor à 3 Current degree of utilisation display p. 11 - 51 à 4 Door unlocking mechanism p. 9 - 155 à...
Page 420 Operating elements for crane operation 9.1 Overview of the operating elements Side panel 9 - 8 Operating manual GMK5150L...
Page 421 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Applying/releasing the parking brake p. 9 - 163 à 2 – Starting the engine p. 9 - 91 à – Set idling speed p. 9 - 91 3 RCL override –...
Page 422 Operating elements for crane operation 9.1 Overview of the operating elements Crane cab, rear 9 - 10 Operating manual GMK5150L...
Page 423 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Cab lighting p. 9 - 147 2 Sun roller blind 1), 3) 3 Radio-CD/USB 4 Loudspeaker à 5 Sockets 12 V p. 9 - 145 6 Fan with switch à...
Page 424: Control Panels
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.3 Control panels Left à 1 Moving the outrigger p. 9 - 102 à 2 Slewing gear on/off p. 9 - 118 à 3 – Lifting limit switch override p.
Page 425 Operating elements for crane operation 9.1 Overview of the operating elements Right à 1 Jog dial (rotary push button) p. 9 - 95 à 2 Main hoist on/off p. 9 - 114 à 3 Derricking gear on/off p. 9 - 120 à...
Page 426: Control Lever Assignment
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.4 Control lever assignment The truck crane can be equipped with two different control lever configurations. 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 427 Operating elements for crane operation 9.1 Overview of the operating elements Version 2 In version 2, the right control lever is configured with the Telescope function. Left control lever Right control lever 1 Slewing to the left Raise/retract 2 Slewing to the right Lower/extend 3 Lower auxiliary hoist Lower the main hoist...
Page 428: Ccs Control Unit
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.5 CCS control unit 9 - 16 Operating manual GMK5150L...
Page 429 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Display CCS p. 9 - 95 à Overview start menu p. 9 - 19 2 Jog dial à 3 Exiting the menu/input mode p. 9 - 98 à...
Page 430: Menu-Independent Displays
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.6 Menu-independent displays à 1 Slewing gear p. 9 - 118 à 2 Telescoping mechanism p. 9 - 122 à 3 Derricking gear p. 9 - 120 à 4 Main hoist p.
Page 431: Ccs - Start Menu
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.7 CCS – Start menu à 1 RCL display p. 9 - 20 à 2 Engine speed display p. 10 - 8 à 3 AdBlue (DEF) filling level indicator p.
Page 432 Operating elements for crane operation 9.1 Overview of the operating elements RCL display à 1 Display Slewing ranges/working radii p. 9 - 21 à 2 Current working radius display p. 9 - 134 à 3 Current slewing angle display p. 9 - 134 à...
Page 433 Operating elements for crane operation 9.1 Overview of the operating elements Display Slewing ranges/working radii A For the Standard slewing range type B For the MAXbase slewing range type à Display of current slewing range divisions p. 9 - 133 à...
Page 434: Ccs - Overview Menu Groups
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.8 CCS – Overview menu groups 9 - 22 Operating manual GMK5150L...
Page 435 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Superstructure menu group p. 9 - 26 – Superstructure lock sub-menu – Counterweight menu à 2 Menu group outrigger/driving p. 9 - 29 – Outrigger menu – Outrigger cylinders menu –...
Page 436 Operating elements for crane operation 9.1 Overview of the operating elements 9 - 24 Operating manual GMK5150L...
Page 437 Operating elements for crane operation 9.1 Overview of the operating elements à 8 Menu group, settings p. 9 - 63 – Crane cab menu – Set display brightness and date/time menu – Switch units menu – Set control lever characteristic curve menu –...
Page 438: Superstructure Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.9 Superstructure menu group à 1 Superstructure lock sub-menu p. 9 - 27 à 2 Counterweight menu p. 9 - 28 9 - 26 Operating manual GMK5150L...
Page 439 Operating elements for crane operation 9.1 Overview of the operating elements Superstructure lock sub-menu à 1 Slewing release display – identical to the display in p. 9 - 28 the Counterweight menu à 2 House lock locking status displays p. 9 - 131 à...
Page 440 Operating elements for crane operation 9.1 Overview of the operating elements Counterweight menu à 1 Slewing release display p. 9 - 113 à 2 Display of slewing direction for automatic mode p. 9 - 110 à 3 Current slewing angle display p.
Page 441: Menu Group Outrigger/Driving
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.10 Menu group outrigger/driving à 1 – Outrigger menu p. 9 - 30 à – Outrigger cylinders menu p. 9 - 32 à 2 Driving menu p. 9 - 34 Operating manual 9 - 29 GMK5150L...
Page 442 Operating elements for crane operation 9.1 Overview of the operating elements Outrigger menu 9 - 30 Operating manual GMK5150L...
Page 443 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Slewing gear/movements locked display p. 9 - 101 à 2 Parking brake/movements locked display/warning p. 9 - 101 à 3 Suspension on/off display/warning p. 9 - 101 à...
Page 444 Operating elements for crane operation 9.1 Overview of the operating elements Outrigger cylinders menu 9 - 32 Operating manual GMK5150L...
Page 445 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Slewing gear/movements locked display p. 9 - 101 à 2 Parking brake/movements locked display/warning p. 9 - 101 à 3 Suspension on/off display/warning p. 9 - 101 à...
Page 446 Operating elements for crane operation 9.1 Overview of the operating elements Driving menu 9 - 34 Operating manual GMK5150L...
Page 447 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Transmission mode RM p. 9 - 160 à 2 Transmission mode R p. 9 - 159 à 3 Neutral position N p. 9 - 159 à 4 Transmission mode D p.
Page 448 Operating elements for crane operation 9.1 Overview of the operating elements Blank page 9 - 36 Operating manual GMK5150L...
Page 449: Rcl/Telescoping Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.11 RCL/Telescoping menu group à 1 Menu enter rigging mode/telescope p. 9 - 38 à 2 Lifting capacity tables menu p. 9 - 44 à 3 Telescoping semi-automation menu p.
Page 450 Operating elements for crane operation 9.1 Overview of the operating elements Menu enter – For the Standard slewing range type rigging mode/ telescope A For the Main boom boom system B For the Lattice extension boom system 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 451 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Enter slewing range p. 9 - 136 à 2 Enter outrigger span p. 9 - 139 à Outrigger span monitoring display p. 9 - 140 à 3 Enter counterweight p.
Page 452 Operating elements for crane operation 9.1 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 453 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Enter slewing range p. 9 - 136 à 2 Input front left outrigger span p. 9 - 139 à 3 Input front right outrigger span p. 9 - 139 à...
Page 454 Operating elements for crane operation 9.1 Overview of the operating elements Pre-selection telescoping menu 9 - 42 Operating manual GMK5150L...
Page 455 Operating elements for crane operation 9.1 Overview of the operating elements Enter desired parameter à 1 Input load p. 9 - 141 à 2 Input working radius p. 9 - 141 à 3 Input main boom length p. 9 - 141 à...
Page 456 Operating elements for crane operation 9.1 Overview of the operating elements à Lifting capacity Displaying the lifting capacity tables , p. 11 - 59 tables menu – For the Standard slewing range type 1 Slewing range display 2 Permissible working range display (range under the curve) I Main hoist display Limitation due to reeving...
Page 457 Operating elements for crane operation 9.1 Overview of the operating elements Telescoping semi- automation menu à 1 Telescopic sections display p. 9 - 124 à 2 Pre-selection for all telescopic sections p. 9 - 124 à 3 Pre-selection individual telescopic sections p.
Page 458 Operating elements for crane operation 9.1 Overview of the operating elements Manual telescoping menu à 1 Locking status telescopic section display p. 9 - 126 à 2 Symbol lock/release telescopic section p. 9 - 126 à 3 Telescoping cylinder in the telescopic section display p.
Page 459: Working Range Limiter Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.12 Working range limiter menu group à 1 Overall height menu p. 9 - 48 à 2 Working radius menu p. 9 - 49 à 3 Slewing angle menu p.
Page 460 Operating elements for crane operation 9.1 Overview of the operating elements Overall height menu 1 Switching monitoring function on/off 2 – Current overall height display – Accepting limit value à 3 – Overall height limit value display p. 11 - 138 –...
Page 461 Operating elements for crane operation 9.1 Overview of the operating elements Working radius menu 1 Switching monitoring function on/off 2 Current working radius display 3 – Current working radius display à – Accepting limit value p. 11 - 140 4 Working radius limit value display 5 –...
Page 462 Operating elements for crane operation 9.1 Overview of the operating elements Slewing angle menu 1 Switching monitoring function on/off 2 – Current slewing angle display – Accepting limit value 3 – Slewing angle A limit value display – Manually entering limit value à...
Page 463 Operating elements for crane operation 9.1 Overview of the operating elements Hoist rope travel limitation menu 1 Switching monitoring function on/off 2 Raise input confirmation 3 Lower input confirmation à 4 Current hoist rope position display p. 11 - 145 5 –...
Page 464: Information 1 Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.13 Information 1 menu group à 1 Hydraulic pressure and fuel consumption menu p. 9 - 53 à 2 Datalogger menu (Menu opens on the display RCL) p. 9 - 81 9 - 52 Operating manual GMK5150L...
Page 465 Operating elements for crane operation 9.1 Overview of the operating elements Hydraulic pressure and fuel consumption menu à 1 Angle gear temperature display p. 9 - 128 à 2 Hydraulic system pressure display p. 9 - 128 Slewing gear circuit à...
Page 466: Heating/Engine/Additional Equipment Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.14 Heating/Engine/Additional equipment menu group à 1 Economy menu p. 9 - 55 à 2 Remote control menu p. 9 - 56 à 3 Heating/air-conditioning menu p. 9 - 57 à...
Page 467 Operating elements for crane operation 9.1 Overview of the operating elements Economy menu à 1 Switching off Economy mode on/off p. 9 - 92 à 2 Set interval 1 p. 9 - 92 à 3 Set interval 2 p. 9 - 92 à...
Page 468 Operating elements for crane operation 9.1 Overview of the operating elements Remote control menu à 1 Remote control menu p. 9 - 132 à 2 Remote control display p. 9 - 132 9 - 56 Operating manual GMK5150L...
Page 469 Operating elements for crane operation 9.1 Overview of the operating elements Heating/air- conditioning menu à 1 Outdoor temperature display p. 11 - 151 à 2 Air distribution p. 11 - 152 à 3 Setting the temperature p. 11 - 151 à...
Page 470 Operating elements for crane operation 9.1 Overview of the operating elements Spotlights menu à 1 Switching automatic spotlights on/off p. 9 - 147 à 2 Increase the slewing speed p. 9 - 147 à 3 Reduce the slewing speed p. 9 - 147 à...
Page 471: Telescoping Emergency Program Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.15 Telescoping emergency program menu group à 1 Telescoping emergency program menu p. 9 - 60 à 2 Unknown telescoping menu p. 9 - 62 Additional equipment Operating manual 9 - 59 GMK5150L...
Page 472 Operating elements for crane operation 9.1 Overview of the operating elements Telescoping emergency program menu XXX sec XXXX mm XXXX mm 9 - 60 Operating manual GMK5150L...
Page 473 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Input access code emergency program p. 14 - 33 à 2 Remaining time emergency program display p. 14 - 33 à 3 Telescoping cylinder length displays p. 14 - 33 4 –...
Page 474 Operating elements for crane operation 9.1 Overview of the operating elements Unknown telescoping menu à 1 Input access code unknown telescoping p. 14 - 41 à 2 Input for telescopic section 1 p. 14 - 41 à 3 Input for telescopic section 2 p.
Page 475: Menu Group, Settings
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.16 Menu group, settings à 1 Crane cab menu p. 9 - 64 à 2 Set display brightness and date/time menu p. 9 - 65 à 3 Switch units menu p.
Page 476 Operating elements for crane operation 9.1 Overview of the operating elements Crane cab menu à 1 Windscreen interval duration selection/display p. 9 - 149 à 2 Selection/display of skylight interval duration p. 9 - 149 à 3 Retract/extend step selection p.
Page 477 Operating elements for crane operation 9.1 Overview of the operating elements Set display This is operated in the same way as in the driver's cab. brightness and date/time menu à 1 Selection setting the display brightness p. 4 - 11 à...
Page 478 Operating elements for crane operation 9.1 Overview of the operating elements Switch units menu 1 Display units in: – Metres – Degrees Celsius – Kilograms – Bar à p. 11 - 128 2 Display units in: – Feet – Degrees Fahrenheit –...
Page 479 Operating elements for crane operation 9.1 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. 11 - 129 5 Auxiliary hoist characteristic curve 6 Lattice extension...
Page 480 Operating elements for crane operation 9.1 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. 11 - 125 5 Enter speed –...
Page 481: Information 2 Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.17 Information 2 menu group à 1 Operating hours menu p. 9 - 70 à 2 Engine/transmission error menu p. 9 - 71 à 3 Crane operation error menu p.
Page 482 Operating elements for crane operation 9.1 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 483 Operating elements for crane operation 9.1 Overview of the operating elements Engine/ This is operated in the same way as in the driver's cab. transmission error menu 1 Display of error / total errors 2 Engine symbol display 3 Transmission symbol display à...
Page 484 Operating elements for crane operation 9.1 Overview of the operating elements Crane operation error menu 1 Display of error / total errors 2 Error message display à 3 To acknowledge the error p. 14 - 8 4 Previous error 5 Next error 9 - 72 Operating manual GMK5150L...
Page 485 Operating elements for crane operation 9.1 Overview of the operating elements Program version menu à 1 Serial number display p. 14 - 3 à 2 Program version display p. 14 - 3 Operating manual 9 - 73 GMK5150L...
Page 486 Operating elements for crane operation 9.1 Overview of the operating elements Blank page 9 - 74 Operating manual GMK5150L...
Page 487: Various Controls
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.18 Various controls à 1 Preheating the hydraulic oil p. 9 - 128 à 2 Camera on/off p. 12 - 156 à 3 Override torque reduction p. 11 - 132 à...
Page 488: Rcl Control Unit
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.19 RCL control unit 1 RCL display à 2 USB connection for data export p. 9 - 142 3 No function à 4 Switch off RCL buzzer p. 9 - 98 à...
Page 489: Menu-Independent Displays
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.20 Menu-independent displays à 1 Warning messages display p. 14 - 10 à 2 Working range limiter displays p. 11 - 136 à 3 RCL status display p. 11 - 51 Operating manual 9 - 77 GMK5150L...
Page 490: Rcl - Menus
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.21 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 491 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Display RCL code p. 11 - 45 à 1),2) 2 Current lattice extension inclination display p. 11 - 50 à 1),2) Angle of the lattice extension display p.
Page 492 Operating elements for crane operation 9.1 Overview of the operating elements à Lifting capacity The same menu is displayed as shown on the CCS display; p. 9 - 44. tables menu Either the Monitoring menu or the Lifting capacity table menu is displayed. Additionally, the Datalogger menu can be manually opened (from the CCS display).
Page 493 Operating elements for crane operation 9.1 Overview of the operating elements Datalogger menu à 1 Export data p. 9 - 142 à 2 Display of export progress p. 9 - 142 à 3 USB connection for data export p. 9 - 142 Operating manual 9 - 81 GMK5150L...
Page 494 Operating elements for crane operation 9.1 Overview of the operating elements Blank page 9 - 82 Operating manual GMK5150L...
Page 495: Hand-Held Control
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.22 Hand-held control à 1 Engine control panel p. 9 - 151 à 2 Pre-select emergency operation p. 9 - 152 à 3 Function buttons p. 9 - 152 4 no function 5 no function à...
Page 496 Operating elements for crane operation 9.1 Overview of the operating elements Blank page 9 - 84 Operating manual GMK5150L...
Page 497: Outriggers Control Units
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.23 Outriggers control units Menu- This function of the illustrated buttons is the same in all the menus. independent This function of the other buttons depends on the opened menu. buttons à...
Page 498 Operating elements for crane operation 9.1 Overview of the operating elements Outrigger menu 9 - 86 Operating manual GMK5150L...
Page 499 Operating elements for crane operation 9.1 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. Outriggers à...
Page 500 Operating elements for crane operation 9.1 Overview of the operating elements Raise axle menu à 1 to 5 Pre-selection display p. 9 - 106 Directional indicator à Wheel load display, opposite p. 9 - 107 à Wheel load display, operator's side p.
Page 501: Short Description Of The Operating Elements
If some operating elements do not work, first read the following chapters which are referred to at the respective places before contacting Manitowoc Crane Care 9.2.1 Definition of information relating to directions of movement...
Page 502: General Rules For Buttons And Symbols On The Display
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.2 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 503: Engine
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.3 Engine à Side panel Starting the engine – from the crane cab , p. 10 - 3. Ignition lock – 0 Ignition off, engine off, key can be removed –...
Page 504: Adblue System
Operating elements for crane operation 9.2 Short description of the operating elements Economy mode menu – Opening: 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 4 Average consumption à...
Page 505 Operating elements for crane operation 9.2 Short description of the operating elements AdBlue system fault à Faults on the Adblue system , p. 8 - 21 1 – On: Torque reduction indicator lamp 1 – On: Reduction in torque the next time the engine is started 1 –...
Page 506: Seat Contact Switch And Dead Man's Switch
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.5 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. Releasing crane functions – Sit down – seat contact switch (2) on –...
Page 507: Crane Control Ccs
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.6 Crane control CCS The GMK5150L 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 508 Operating elements for crane operation 9.2 Short description of the operating elements In the menu area – For selecting and opening menus. One symbol is always selected. Select a menu 1 Slewing 2 Press – The next symbol is marked. Menu, open 1 Press 3 Press...
Page 509 Operating elements for crane operation 9.2 Short description of the operating elements In the operating area – 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 510 Operating elements for crane operation 9.2 Short description of the operating elements Exiting the menu/input mode Press button (1) or (2) to exit the menu or input mode. – Press the button – The opened menu closes – the menu from the once: next higher level is opened –...
Page 511 Operating elements for crane operation 9.2 Short 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 512: Outrigger - Crane Cab
Operating elements for crane operation 9.2 Short description of the operating elements Emergency stop switch May only be used in an emergency. – Press: Engine off – crane functions stop immediately. Switch latches – Turn the latched Switch returns to initial position – crane functions switch: released à...
Page 513 Operating elements for crane operation 9.2 Short description of the operating elements CCS display Outrigger menu – Opening: Select and confirm symbol (1) Slewing gear/movements locked display – Red: Slewing gear switched off – symbol (1) out – Green: Slewing gear switched on – outrigger movement disabled – symbol (1) is displayed à...
Page 514 Operating elements for crane operation 9.2 Short description of the operating elements Outrigger control units on/off – Switch on: Select symbol (2) and confirm – symbol (1) is grey – Switch off: Select symbol (1) and confirm – symbol (2) is grey à...
Page 515: Outrigger Control Units
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.8 Outrigger control units à Extending/retracting outrigger beams , p. 12 - 49 à Extending/retracting supporting cylinders , p. 12 - 56 à All directional information relates to the carrier; p.
Page 516 Operating elements for crane operation 9.2 Short description of the operating elements Horn The ignition must be switched on. 1 – Press: Carrier horn on Outrigger menu The operating elements for the outriggers are only active when the Outrigger menu is open. Outrigger menu –...
Page 517 Operating elements for crane operation 9.2 Short description of the operating elements Operating the right outriggers (next to control unit) Operation is the same as on the button unit for Outriggers to the left of display field . Extending/retracting all outrigger cylinders Button (3) or (4) is pressed.
Page 518: Raise Axle
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.9 Raise axle à Operating the axle raising system , p. 12 - 66 Raise axle menu The suspension is switched off (locked). – Opening: 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 519 Operating elements for crane operation 9.2 Short 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 520: Inclination Indicators
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.10 Inclination indicators à Inclination indicators , p. 12 - 60 Display of current inclination A In the Monitoring menu B In the Outrigger menu C On the Outrigger control units 1 Measuring range display 2 Inclination indicator 3 Directional indicator...
Page 521: Outrigger Pressure Displays
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.11 Outrigger pressure displays Outrigger menu Outrigger pressure display – Unit of measurement: Displayed depending on setting – t – tons or – klbs – kilopounds – (1 kilopound = 1,000 lbs) –...
Page 522: Counterweight Menu
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.13 Counterweight menu à Rigging/unrigging the counterweight , p. 12 - 71, à Counterweight hoist unit , p. 12 - 102. – Opening: Select and confirm symbol (1) Rigging position display 1 White –...
Page 523 Operating elements for crane operation 9.2 Short 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 524 Operating elements for crane operation 9.2 Short description of the operating elements Lifting cylinder position display The current position of the counterweight lifting cylinders is shown by different symbols: 1 Green – extended 2 Green – retracted 3 Yellow – intermediate position 4 Violet –...
Page 525 Operating elements for crane operation 9.2 Short description of the operating elements Slewing release display 1 Green: Slewing enabled (if no other shutdown has occurred). 2 Red: Slewing disabled by counterweight – the corresponding warning is displayed. The pre-tensioning pressure is too low or the counterweight is not completely lifted.
Page 526: Main Hoist
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.14 Main hoist Control panels Main hoist on/off There is a lamp in the button. – Press once: – Lamp bright – main hoist on – Lamp dim – main hoist off à...
Page 527 Operating elements for crane operation 9.2 Short description of the operating elements High speed monitoring for the hoist – On: High-speed mode on – Out: High-speed mode off à p. 11 - 113 Lift/lower the hoist display – Symbol (1): Lifting –...
Page 528: Auxiliary Hoist
Operating elements for crane operation 9.2 Short description of the operating elements Warning for lifting limit switch shutdown 1 – On: Lifting limit switch triggered – movements which increase the load moment stops 1 – Flashing: Button (2) pressed 1 – Out: Lifting limit switch not triggered and not bridged à...
Page 529 Operating elements for crane operation 9.2 Short description of the operating elements CCS display Power units display – Green: Auxiliary hoist on – Red: Auxiliary hoist off High speed monitoring for the hoists – On: High-speed mode on – Out: High-speed mode off à...
Page 530: Slewing Gear
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.16 Slewing gear à Slewing gear , p. 11 - 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 531 Operating elements for crane operation 9.2 Short description of the operating elements CCS display Power units display – Green: Slewing gear on – Red: Slewing gear off Slewing gear brake engaged/released 1 On: Slewing gear brake applied 1 Out: Slewing gear brake released à...
Page 532: Derricking Gear
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.17 Derricking gear à Derricking gear , p. 11 - 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 533 Operating elements for crane operation 9.2 Short 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 – Out: High-speed mode off à...
Page 534: Telescoping Mechanism
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.18 Telescoping mechanism à Control panels Telescoping mechanism , p. 11 - 89. 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 off –...
Page 535 Operating elements for crane operation 9.2 Short description of the operating elements CCS display Telescoping mechanism high-speed mode inspection – On: High-speed mode on – Out: High-speed mode off à p. 11 - 113 Power units display – Green: Telescoping mechanism on –...
Page 536 Operating elements for crane operation 9.2 Short description of the operating elements Telescoping cylinder length display – Display: Current extended length of the telescoping cylinder – Unit of Displayed in % (per cent) and, depending on setting, measurement mm (millimetres) or ft (feet) à...
Page 537 Operating elements for crane operation 9.2 Short description of the operating elements Pre-selection individual telescopic sections 1 - 5 Display of telescopic sections 1 to 5 Confirm pre-selection 1 Confirm pre-selected telescoping 2 Telescoping permitted display 3 Telescoping not permitted display à...
Page 538 Operating elements for crane operation 9.2 Short description of the operating elements Locking point display 1 Extend telescoping cylinder 2 Retract telescoping cylinder Locking/releasing the telescoping cylinder – To lock: – Telescopic section locked: Select symbol (2) and confirm – telescoping cylinder is locked –...
Page 539 Operating elements for crane operation 9.2 Short description of the operating elements Main boom length display – Display: Current extended length of the main boom – Unit of Displayed depending on setting, mm (millimetres) or measurement ft (feet) à p. 11 - 101 Locking point display 1 Extend telescoping cylinder 2 Retract telescoping cylinder...
Page 540: Hydraulic System
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.19 Hydraulic system Inclining the crane cab – Press down: Incline forward – Press up: Incline back à p. 11 - 123 In Information menu 1 Angle gear oil temperature Current pressure in bar for movements of: 2 Slewing gear 3 Telescoping mechanism...
Page 541: Superstructure Lock/House Lock Menu
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.20 Superstructure lock/house lock menu – Opening: Select and confirm symbol (1) à Locking/unlocking the superstructure , p. 11 - 15. Superstructure lock Locking status displays The current position of the locking pin is shown by different symbols: 1 and 7 Red –...
Page 542 Operating elements for crane operation 9.2 Short description of the operating elements Current slewing angle display 0° to the rear position – locking point 0°: 180° to the front position – 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 543 Operating elements for crane operation 9.2 Short description of the operating elements à Houselock Switching the houselock on/off , p. 11 - 17. Locking status displays The current position of the locking pin is shown by different symbols: 1 Unlocked 2 Intermediate position 3 Blocked, locking pin in front of a tooth 4 Locked...
Page 544: Remote Control
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.21 Remote control Operating with the remote control is only enabled for the Standard slewing range type. Remote control menu 1 – Orange: Remote control connected 1 – Green: Remote control switched on.
Page 545: Rated Capacity Limiter (Rcl)
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.22 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 546 Operating elements for crane operation 9.2 Short 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 547 Operating elements for crane operation 9.2 Short description of the operating elements Maximum permissible speed display Separate displays are provided for each direction of movement. 1 Slewing to the left 2 Slewing to the right 3 Lower the main hoist 4 Lift the main hoist 5 Lower the auxiliary hoist 6 Lifting the auxiliary hoist...
Page 548 Operating elements for crane operation 9.2 Short description of the operating elements In the Enter rigging mode/telescope status menu Select and confirm the symbol (1) – the menu opens, and opens automatically after Ignition on Enter slewing range In input mode Select slewing range symbol and confirm –...
Page 549 Operating elements for crane operation 9.2 Short description of the operating elements Reeving input mode display 1 Main hoist 2 Auxiliary hoist Orange: Grey: à Enter rigging mode , p. 11 - 32 Enter reeving 1 Main hoist In input mode – select and confirm current reeving 2 Auxiliary hoist –...
Page 550 Operating elements for crane operation 9.2 Short 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 551 Operating elements for crane operation 9.2 Short 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 552 Operating elements for crane operation 9.2 Short 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 553 Operating elements for crane operation 9.2 Short description of the operating elements In the Pre-selection telescoping menu à Pre-selecting telescoping , p. 11 - 40 Enter desired parameter In input mode – select and confirm parameters (1), (2). 1 Selection of numerical values 2 Selection by marking the segments –...
Page 554 Operating elements for crane operation 9.2 Short description of the operating elements In the Datalogger menu à Datalogger , p. 11 - 68 – Opening: Select and confirm symbol (1) In the Datalogger menu RCL display à Datalogger , p. 11 - 68 USB connection for data export 1 Connect the USB stick –...
Page 555 Operating elements for crane operation 9.2 Short 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. 9 - 144. Overriding the RCL RCL shutdown overridden –...
Page 556 Operating elements for crane operation 9.2 Short 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. 9 - 143. Overriding the RCL in an emergency RCL shutdown overridden –...
Page 557: Electrical System
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.23 Electrical system Voltage monitoring warning – Display symbol: Engine on – power failure – switch off engine – Out: Engine on – no fault à p. 10 - 8 Sockets 12 V 1 Socket 12 V/max.
Page 558: Lighting, Windscreen Wiper/Washing System
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.24 Lighting, windscreen wiper/washing system Lighting Air traffic control light on/off Select symbol (1) and confirm – symbol ON is displayed – Switch on: Select symbol (2) and confirm – symbol OFF is displayed –...
Page 559 Operating elements for crane operation 9.2 Short description of the operating elements Slewable spotlights on/off – Switch on: Push down – lamp in the button on – Switch off: Push up – lamp in the button off à p. 11 - 130 Slew slewable spotlight –...
Page 560 Operating elements for crane operation 9.2 Short description of the operating elements Reading lamp 1 On 2 Off Windscreen wiper/washing system Windscreen wiper on/off – Off: Middle position – Interval: Push up – wiper goes to end position – Continuous Push down operation: Roof window wiper on/off...
Page 561 Operating elements for crane operation 9.2 Short description of the operating elements Crane cab menu Opening: 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 562: Hand-Held Control
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.25 Hand-held control Sockets for hand- The following applies to all sockets: held control – Pull plug: Engine off – ignition off – Insert plug: Switch the ignition on à...
Page 563 Operating elements for crane operation 9.2 Short description of the operating elements à Engine control Starting the engine – with the hand-held control , p. 10 - 10 panel 1 Voltage monitoring – On: Switch the ignition on – Out: Switch the ignition off 2 CAN monitoring –...
Page 564 Operating elements for crane operation 9.2 Short description of the operating elements 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 derricking gear Actuation is the same for all buttons –...
Page 565 Operating elements for crane operation 9.2 Short description of the operating elements Pre-selected power unit Telescoping Derricking Slewing Lattice Button Hoists mechanism gear gear extension combination Lower Lowering Lower Retract Raise Lifting Raise Slew to right Slew to left à Emergency operation with the hand-held control , p.
Page 566: Windows And Doors
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.26 Windows and doors window 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 567 Operating elements for crane operation 9.2 Short 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 568: Diagnostics
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.27 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 and RCL control...
Page 569: 9.3 Short Description Of The Operating Elements - Driving From The Crane Cab
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Short description of the operating elements – driving from the crane cab 9.3.1 Driving menu Driving menu – Opening: Select symbol (1) and confirm – menu is opened The menu is also opened the first time the parking brake is à...
Page 570 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Steering lock display White: Driver's cab: Ignition key in position 1 Crane cab: Operating elements for driving active Red: Driver's cab: Ignition key not in position 1 Crane cab: Operating elements for driving without function à...
Page 571: Transmission
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab 9.3.2 Transmission Operating the transmission when driving with rigged truck crane, à Operating the transmission , p. 13 - 28. The following applies to all operating elements: –...
Page 572 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Transmission mode DM – Switch on: Select and confirm symbol – letter is white – Gear 1 forwards on – transmission will not shift –...
Page 573: Final Drive
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab 9.3.3 Final drive Driving menu Opening: Select symbol (1) and confirm – menu is opened Transverse differential locks on/off – Switch on: Select symbol (1) and confirm –...
Page 574: Brakes
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab 9.3.4 Brakes Service brake The pedal acts on the carrier brakes – for continuously variable adjustment of the braking force. CCS display Supply pressure brake circuits 1 and 2 display –...
Page 575: Steering
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Applying/releasing the parking brake – Applying: – Press down once – lamp (1) lights up, Parking brake applied – Releasing: Releasing for the first time after ignition on –...
Page 576 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab CCS display Changing the steering direction Display 1 Steering direction Steering wheel 2 Steering direction Reversed (compared to steering wheel) To switch over: Select desired symbol and confirm The setting will be secured –...
Page 577 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Switching steering modes on and off The selected symbol must be confirmed within 2 seconds, otherwise the steering mode remains unchanged. Automatic separate steering for driving around corners on/off –...
Page 578 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Control panels The information in this section is based on the steering direction setting Steering wheel . Steering with separate steering – manual The (3) symbol is displayed 1.
Page 579: Starting/Switching Off The Engine - For Crane Operation
Starting/switching off the engine – for crane operation 10.1 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 580 Starting/switching off the engine – for crane operation 10.1 When starting the engine for the first time in the day When not driving from the crane cab: • Remove the ignition key. If you want to drive from the crane cab: •...
Page 581: Starting The Engine - From The Crane Cab
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2 Starting the engine – from the crane cab 10.2.1 Check the fuel level and AdBlue level • Check the fuel level and the AdBlue level if necessary, before starting the engine.
Page 582: Checks Before Starting The Engine
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.2 Checks before starting the engine Checks on the All checks and switch positions for the first engine start of the day must be à...
Page 583: Switching The Ignition On
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.3 Switching the ignition on Do not start the engine until the CCS display shows a menu (usually the Enter rigging mode menu). •...
Page 584: Comparison Of Switching States
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.4 Comparison of switching states When the ignition is switched on, the switching states of the differential locks and the steering are compared. Differential locks The state last saved is retrieved.
Page 585: Starting The Engine
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.6 Starting the engine This section pertains 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. The starter fuel sprayed into the intake manifold can ignite.
Page 586: Checks After Starting The Engine
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.7 Checks 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 587: Setting The Idling Speed
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.8 Setting the idling speed à • Start the engine; p. 10 - 7. • Open the start menu – button (1). The display (2) shows the current engine speed You can increase the idling speed for crane operation.
Page 588: Starting The Engine - With The Hand-Held Control
Starting/switching off the engine – for crane operation 10.3 Starting the engine – with the hand-held control 10.3 Starting the engine – with the hand-held control You can only start the engine when bridging plugs are inserted in all sockets à...
Page 589: Switch Off The Engine
Starting/switching off the engine – for crane operation 10.4 Switch off the engine 10.4 Switch off the engine 10.4.1 At the ignition lock and with hand-held control Risk of accident by 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 590: Using The Emergency Stop Switches
Starting/switching off the engine – for crane operation 10.4 Switch off the engine 10.4.3 Using 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. Stopping crane movements suddenly may cause the truck crane to become overloaded under unfavourable conditions.
Page 591: Crane Operation
Crane operation 11.1 Before operating the crane Crane operation 11.1 Before operating the crane 11.1.1 CHECKLIST: Checks before operating the crane This checklist is not a complete operating manual. There are accompanying operating 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 592 Crane operation 11.1 Before operating the crane à 3. – Switch on the cameras for crane operation; p. 12 - 150. à – Adjust the slewable spotlights if necessary; p. 11 - 130. à 4. Crane cab heater – check the fuel level; p.
Page 593 Crane operation 11.1 Before operating the crane à 9. Check the position of the hoist ropes; p. 11 - 6. 10. Compare current rigging mode with the RCL display – enter and con- à firm current rigging mode, if necessary; p.
Page 594 Crane operation 11.1 Before operating the crane à 14. Check hydraulic oil temperature, preheat if necessary; p. 11 - 14. à 15. Adjust the brightness of the CCS display if necessary; p. 10 - 6. Additional information on inspections during crane operation, on permissi- ble working positions and on how to operate the individual power units;...
Page 595: Check The Condition Of The Truck Crane
Crane operation 11.1 Before operating the crane 11.1.2 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 596 Crane operation 11.1 Before operating the crane Checking the posi- tion 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 being drawn in or crushed. •...
Page 597 Crane operation 11.1 Before operating the crane • Checking the Check the following functions and have faulty parts repaired. electrical system – Working area spotlight – Air traffic control light, rotating beacons – Windscreen wipers, windscreen washing system – Horn Operating manual 3 302 709 en 11 - 7...
Page 598: Adjusting The Crane Cab Seat And Front Control Panel
Crane operation 11.1 Before operating the crane 11.1.3 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 599 Crane operation 11.1 Before operating the crane Front control You can adjust the height and inclination. panel • Pull and hold the handle (1). • Adjust the front panel to suit your requirements. • Release the handle (1). In addition, the inclination of the display can be adjusted: •...
Page 600: 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 à...
Page 601 Repeat the checks with the emergency stop switches (1) and (2) If the emergency off switch is not working correctly, do not start work with the crane but notify Manitowoc Crane Care Operating manual 3 302 709 en 11 - 11...
Page 602 3 seconds. If the dead man's switch system is not working correctly, do not start work with the crane but notify Manitowoc Crane Care 11 - 12 3 302 709 en Operating manual...
Page 603: Earthing The Load
Crane operation 11.1 Before operating the crane 11.1.5 Earthing the load à Even if the truck crane is already earthed ( p. 12 - 15), 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 604: Preheating Hydraulic Oil
Crane operation 11.1 Before operating the crane 11.1.6 Preheating 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 605: Locking/Unlocking The Superstructure
Crane operation 11.1 Before operating the crane 11.1.7 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 606 (2) and shows symbol (6) when the super- structure is locked. The symbol (7) disappears. 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 during a rigging mode for 0°...
Page 607: Switching The Houselock On/Off
Crane operation 11.1 Before operating the crane 11.1.8 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 slewing gear. •...
Page 608 Crane operation 11.1 Before operating the crane Switching on the houselock • Select the symbol (5). • Press the button until the symbol (4) is displayed – 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 609 Crane operation 11.1 Before operating the crane • Switching off the Check that the slewing gear is switched off, and switch if off if it is not; à Switching off the slewing gear , p. 11 - 17. houselock Risk of damage during slewing! Always switch off the slewing gear before you operate the houselock.
Page 610 Crane operation 11.1 Before operating the crane Blank page 11 - 20 3 302 709 en Operating manual GMK5150L...
Page 611: Standard Slewing Range Type
Crane operation 11.2 Standard slewing range type 11.2 Standard slewing range type The MAXbase slewing range type is available in the case of additional à MAXbase slewing range type , p. 11 - 23. equipment; The Standard slewing range type is always available. The supplied lifting capacity tables with symmetrical outrigger spans apply.
Page 612 Crane operation 11.2 Standard slewing range type Blank page 11 - 22 3 302 709 en Operating manual GMK5150L...
Page 613: Maxbase Slewing Range Type
Crane operation 11.3 MAXbase slewing range type 11.3 MAXbase slewing range type This slewing range type is available in addition to the Standard slewing à Permissible slewing ranges and working positions , p. 11 - 21. range type; You must decide between the two slewing range types when entering the rigging mode.
Page 614: Specifications In The Lifting Capacity Tables
Crane operation 11.3 MAXbase slewing range type 11.3.1 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. Superstructure Positional reference position...
Page 615 Crane operation 11.3 MAXbase slewing range type 11.3.2 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 3.800 m (12.5 ft) This case applies only to a symmetrical outrigger span with a span of 7.600 m (24.9 ft).
Page 616 Crane operation 11.3 MAXbase slewing range type Smallest individual width 2.950 m (9.7 ft) This case applies when one or more outrigger beams is extended to a span of 2.950 m (9.7 ft) and all other outrigger beams are extended to larger spans.
Page 617: Enabled Slewing Ranges
Crane operation 11.3 MAXbase slewing range type Smallest individual width 1.250 m (4.1 ft) This case applies when one outrigger beam is extended to a span of 1.250 m (4.1 ft) and all other outrigger beams are extended to larger spans. Positional reference Angular range Enabled slewing range...
Page 618: Lifting Capacities And Slewing Ranges For Outrigger Spans Without Separate Lifting Capacity Tables
Crane operation 11.3 MAXbase slewing range type 11.3.3 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 619: Operation Of The Rated Capacity Limiter
Crane operation 11.4 Operation of the rated capacity limiter 11.4 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 620: Switch On The Rcl
Risk of accidents in the event of faulty safety devices! 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 621 Crane operation 11.4 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 622: Enter Rigging Mode
Crane operation 11.4 Operation of the rated capacity limiter 11.4.2 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 623 Crane operation 11.4 Operation of the rated capacity limiter Enter the slewing Possible types are the Standard slewing range type and, with the corresponding 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 624 Crane operation 11.4 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 625 Crane operation 11.4 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.
Page 626 Crane operation 11.4 Operation of the rated capacity limiter Outrigger span You can adopt the outrigger span provided by the outrigger width monitoring 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 627 Crane operation 11.4 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 7.600 m (24.9 ft) 3.800 m (12.5 ft)
Page 628 Crane operation 11.4 Operation of the rated capacity limiter Counterweight • Select and confirm the display (1). • Select the rigged counterweight combina- tion, for example, 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 629 Crane operation 11.4 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, for example, display (1) for the main hoist – symbol (3) is orange.
Page 630: Pre-Selecting Telescoping
Crane operation 11.4 Operation of the rated capacity limiter Entering the You must enter the RCL code for the rigging mode according to the Lifting capacity table . RCL code • Refer to the Lifting capacity table for the current rigging mode. The corresponding RCL code (1) is specified at the bottom of the table (e.g.
Page 631: Confirm The Rigging Mode And Lifting Capacity Table
Crane operation 11.4 Operation of the rated capacity limiter 11.4.4 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 632 Crane operation 11.4 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 633 Crane operation 11.4 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 634 Crane operation 11.4 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 635: Checks Before Operating The Crane
Crane operation 11.4 Operation of the rated capacity limiter 11.4.5 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 commands on the CCS display.
Page 636 Crane operation 11.4 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 637 Crane operation 11.4 Operation of the rated capacity limiter Hoist checking You must check that the RCL uses the correct reeving data. The RCL always uses the reeving data for the first hoist to be switched on. • Check the symbol (1) or (2) for the hoist with which you wish to lift the load.
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Page 639: Display During The Crane Operation
Crane operation 11.4 Operation of the rated capacity limiter 11.4.6 Display during the 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 640 Crane operation 11.4 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, for example, -3°. A luffing jib is connected.
Page 641 Crane operation 11.4 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 642 Crane operation 11.4 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 643 Crane operation 11.4 Operation of the rated capacity limiter On the CCS display After confirming a permissible rigging mode, the Start menu opens automatically. Slewing range type Standard à If the MAXbase slewing range type has been entered; p. 11 - 55. The RCL display differs according to the confirmed slewing range.
Page 644 Crane operation 11.4 Operation of the rated capacity limiter Limited slewing range The diagram (1) shows the enabled slewing range and the slewing range limits (3), for example, +30° and -30°. – When telescoping or derricking The diagram (1) remains at the current posi- tion.
Page 645 Crane operation 11.4 Operation of the rated capacity limiter Slewing range type MAXbase à If the Standard slewing range type has been entered; p. 11 - 53. Display of the slewing ranges The RCL display represents the four enabled slewing ranges in a diagram with four regions.
Page 646 Crane operation 11.4 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 647: Rcl Early Warning
Crane operation 11.4 Operation of the rated capacity limiter 11.4.7 RCL early warning If about 90% of the maximum permissible load is exceeded, an RCL early warning will be issued. – An intermittent buzzer tone will sound. After five seconds, you can switch off the buzzer tone using button (3) or (4).
Page 648 Crane operation 11.4 Operation of the rated capacity limiter – All crane movements which increase the load moment will be switched off. – A continuous buzzer tone will sound. After five seconds, you can switch off the buzzer tone using button (6) or (7). –...
Page 649: Displaying The Lifting Capacity Tables
Crane operation 11.4 Operation of the rated capacity limiter 11.4.9 Displaying the lifting capacity tables Open menu • Open the Lifting capacity table menu (1) on the CCS control unit. Exiting the menu • Press the button (1) or press the button (2) on the CCS control unit once – the Start menu opens.
Page 650 Crane operation 11.4 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, for example, maximum load 12 t II Display for main hoist, for example, maximum load 18 t Slewing range display...
Page 651 Crane operation 11.4 Operation of the rated capacity limiter à Slewing range If the Standard slewing range type has been entered; p. 11 - 59. type MAXbase 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 652 Crane operation 11.4 Operation of the rated capacity limiter Slewing range display The display is same in all four slewing ranges. 1 Coloured: Enabled slewing range, for example, blue 2 Yellow/red: Shutdown range for maximum working radius 3 White: Shutdown range for minimum working radius – display only when the lifting capacity table specifies a limitation When slewing The symbol (1) for the superstructure always...
Page 653: Rcl Override - Version A
Crane operation 11.4 Operation of the rated capacity limiter 11.4.10 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. 11 - 67. In the case of other entries;...
Page 654 Crane operation 11.4 Operation of the rated capacity limiter When rigging For rigging work, you can: à – override the lifting limit switch; p. 11 - 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 655 Crane operation 11.4 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 656 Crane operation 11.4 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.
Page 657: Rcl Override - Version B
Crane operation 11.4 Operation of the rated capacity limiter 11.4.11 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 658: Datalogger
Crane operation 11.4 Operation of the rated capacity limiter 11.4.12 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 Datalogger (1) menu. Export data You require a USB Stick (USB 2.0 / FAT32 file system / approx.
Page 659 Crane operation 11.4 Operation of the rated capacity limiter Display the data You need the CraneEvaluation program in order to display the exported data. The installation program is located in the CraneEvaluation folder on the Owner's USB stick supplied. Import data •...
Page 660 Crane operation 11.4 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 661 Crane operation 11.4 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 662 Crane operation 11.4 Operation of the rated capacity limiter Blank page 11 - 72 3 302 709 en Operating manual GMK5150L...
Page 663: Crane Operation With Main Boom
Crane operation 11.5 Crane operation with main boom 11.5 Crane operation with main boom 11.5.1 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 664 Crane operation 11.5 Crane operation with main boom Checking the Strong winds can result in the truck crane becoming overloaded. 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 665: Main Hoist
Crane operation 11.5 Crane operation with main boom 11.5.2 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 666 Crane operation 11.5 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 667 Crane operation 11.5 Crane operation with main boom Lifting 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. 11 - 129. lowering ditions; Risk of accidents due to gaps in monitoring Operation of the hoist will only be monitored fully if: à...
Page 668 Crane operation 11.5 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 and reeving. rope speed The scale of the limitation is specified in the supplied lifting capacity table. à...
Page 669: Auxiliary Hoist
Crane operation 11.5 Crane operation with main boom 11.5.3 Auxiliary hoist Risk of accidents when operating the auxiliary hoist Read and observe all of the safety instructions in the section titled Main hoist , p. 11 - 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 670 Crane operation 11.5 Crane operation with main boom • Check whether the current reeving of the auxiliary hoist is displayed, à for example, 6. Correct the reeving if necessary; p. 11 - 39. Lifting and You can adjust the sensitivity of the control levers to suit the operating à...
Page 671 Crane operation 11.5 Crane operation with main boom You can set the desired engine speed (idling speed) with button (1); à p. 10 - 9. Maximum The maximum permissible hoist rope speed is limited automatically permissible hoist depending on the degree of utilisation of the lifting capacity and reeving. The scale of the limitation is specified in the supplied Lifting capacity table .
Page 672: Lifting Limit Switch And Lowering Limit Switch
Crane operation 11.5 Crane operation with main boom 11.5.4 Lifting limit switch and lowering limit switch à Lifting limit switch To install/remove the lifting limit switch; p. 12 - 139. The lifting limit switch (1) prevents the hook block being lifted up to the main boom head and damaging it.
Page 673 Crane operation 11.5 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 operating instructions for carrying out maintenance or rigging work.
Page 674 Crane operation 11.5 Crane operation with main boom Lowering limit switch The lowering limit switch (1) prevents the hoist rope being reeled com- pletely off the drum. The lowering limit switch works only if the switch-off point is set correctly à...
Page 675: Derricking Gear
Crane operation 11.5 Crane operation with main boom 11.5.5 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 676 Crane operation 11.5 Crane operation with main boom Raising and You can adjust the sensitivity of the control levers to suit the operating à Setting the characteristic curves for the control levers , p. 11 - 129. lowering conditions; Risk of accident due to unexpected crane movements! If assigned more than one function, check whether the Derricking control lever function is switched on before you move the control lever for derrick- ing.
Page 677 Crane operation 11.5 Crane operation with main boom You can set the desired engine speed (idling speed) with button (1); à p. 10 - 9. Maximum The maximum permissible derricking speed is limited automatically derricking speed depending on the system length. The scale of the limitation is specified in the supplied Lifting capacity table .
Page 678 Crane operation 11.5 Crane operation with main boom Switching off the If the derricking gear is not required, it should be switched off to avoid unin- derricking gear tentional use. • Press the button (1) once. – The lamp in the button (1) will light up dimly. –...
Page 679: Telescoping Mechanism
Crane operation 11.5 Crane operation with main boom 11.5.6 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 proc- esses at the right time.
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Page 681 Crane operation 11.5 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 682 Crane operation 11.5 Crane operation with main boom Telescoping This state should be the starting point for a telescoping process. process Telescoping processes consist of 4 steps. 1. unlocking the telescoping cylinder The locking pins (5) retract – the telescoping cylinder is unlocked.
Page 683 Crane operation 11.5 Crane operation with main boom 3. Unlocking the telescopic section (A) – The telescoping cylinder extends until the locking pins (7) are clear. (B) – The mechanism (10) retracts the locking pins (7) – the telescopic section is unlocked. 4.
Page 684 Crane operation 11.5 Crane operation with main boom Assignment The CCS display shows a sectional view of the main boom in the menus. 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 685 Crane operation 11.5 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 ing length displayed automatically.
Page 686 Crane operation 11.5 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 interme- diate/telescoping lengths in different ways.
Page 687 Crane operation 11.5 Crane operation with main boom Inspections prior When the ignition is turned on, CCS registers the displayed telescoping to starting status from the current status of the telescoping mechanism and the operations previously saved locking and unlocking procedures. Normally, CCS detects differences between the current and the displayed à...
Page 688 Crane operation 11.5 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 689 Crane operation 11.5 Crane operation with main boom The distance between the hook block and the boom head changes during telescoping. Ensure that the hook block does not trigger the lifting limit switch or touch the ground. • Additionally carry out the following movements –...
Page 690 Crane operation 11.5 Crane operation with main boom à You can switch on high-speed mode for a higher speed; p. 11 - 113. You can set the desired engine speed (idling speed) with button (1); à p. 4 - 17. You can limit the maximum telescoping speed in the Power unit speeds menu;...
Page 691 Crane operation 11.5 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 692 Crane operation 11.5 Crane operation with main boom Current telescoping The display (1) shows how far the telescoping cylinder is extended, for example, 98%. The display (2) shows the current main boom length. The display (3) shows the corresponding telescopic section, for example, telescopic section 3 .
Page 693 Crane operation 11.5 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 694 Crane operation 11.5 Crane operation with main boom Unlocking • Select and confirm the symbol (1). The locking pins (2) retract. – Yellow: Intermediate position – Red: Unlocked – symbol (3) displayed 11 - 104 3 302 709 en Operating manual GMK5150L...
Page 695 Crane operation 11.5 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 696 Crane operation 11.5 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 697 Crane operation 11.5 Crane operation with main boom Unlocking the Unlocking a telescopic section is required for the telescopic section to be tel- telescopic section escoped. The telescoping cylinder and the telescopic section cannot be unlocked simultaneously. Prerequisites – Telescoping mechanism on – symbol (3) green –...
Page 698 Crane operation 11.5 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 699 Crane operation 11.5 Crane operation with main boom Locking the tele- Every telescopic section can be locked at the fixed lengths – fixed lengths; à scopic section p. 11 - 95. Prerequisites – Telescoping mechanism on – symbol (3) green –...
Page 700 Crane operation 11.5 Crane operation with main boom Locking the tele- 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 scopic section for à...
Page 701 Crane operation 11.5 Crane operation with main boom Confirming the entry • Select and confirm the symbol (1). Telescoping • Move the control lever for the displayed tel- escoping direction. 2 Extension 3 Retraction of the telescoping 4 Display in the case of return runs (without a telescopic section) End telescoping semi-automation The teleautomation will stop when the entered...
Page 702 Crane operation 11.5 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 703: High-Speed Mode
Crane operation 11.5 Crane operation with main boom 11.5.7 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 movements Reduce the engine speed before starting high-speed mode.
Page 704 Crane operation 11.5 Crane operation with main boom 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 705: Slewing Gear
Crane operation 11.5 Crane operation with main boom 11.5.8 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 706 Crane operation 11.5 Crane operation with main boom Switching on the After the ignition is switched on, all of the power units will be switched off slewing gear and the lamps in the corresponding buttons will light up only dimly. •...
Page 707 Crane operation 11.5 Crane operation with main boom Slewing The following requirements must be fulfilled before slewing: à – Houselock is switched off; p. 11 - 17. à – The superstructure must be unlocked; p. 11 - 15. à – Slewing is permissible with the current rigging mode; p.
Page 708 Crane operation 11.5 Crane operation with main boom With the Brake pedal function switched on, slewing movements are not braked automatically. If you let go of the control lever or move it to initial à Braking the slew- position, the slewing movement will slowly run down; ing movement , p.
Page 709 Crane operation 11.5 Crane operation with main boom Braking the slew- You may only brake the slewing movement with the slewing gear brake. ing 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 710 Crane operation 11.5 Crane operation with main boom Switching off the If the slewing gear is not required, it should be switched off to avoid unin- slewing gear tentional use. Risk of damage to the main boom Brake the slewing movement down to a standstill before you switch off the slewing gear.
Page 711: Switching The Reduction Of Slewing Speed On And Off
Crane operation 11.5 Crane operation with main boom 11.5.9 Switching the reduction of slewing speed on and off When the ignition is switched on the reduction of slewing speed is switched on and depending on the degree of utilisation and the working radius, the slewing speeds are automatically reduced to the maximum permissible lev- els listed in the Lifting capacity table under the comments on slewing speed.
Page 712: Possible Movement Combinations
Crane operation 11.5 Crane operation with main boom Switching reduction on • Select and confirm the symbol (2). – Symbol (1) – grey displayed. – The warning message (3) disappears. The slewing speed is reduced automatically. The reduction is automatically switched on when you enter the slewing range type MAXbase .
Page 713: Settings And Displays For Crane Operation
Crane operation 11.6 Settings and displays for crane operation 11.6 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. 11.6.1 Inclining the crane cab With the appropriate equipment, you can incline the crane cab to the rear in...
Page 714: Idling Speed, Setting
Crane operation 11.6 Settings and displays for crane operation 11.6.2 Idling speed, setting à Setting the idling speed , p. 10 - 9 11.6.3 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 715: Limiting The Power Unit Speeds
Crane operation 11.6 Settings and displays for crane operation 11.6.4 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 (1). The values below the symbols (1) to (6) indi- cate the currently set power unit speeds.
Page 716: Economy Mode
Crane operation 11.6 Settings and displays for crane operation 11.6.5 Economy mode You can also switch economy mode on/off. If you do not move the control lever when Economy mode is switched on, then the engine speed is automat- ically reduced in two steps. If the crane truck is also equipped with APS (Auxiliary Power Supply), there is a further third step in which the engine is shut down and an external generator started.
Page 717 Crane operation 11.6 Settings and displays for crane operation Economy steps The economy steps 1 to 3: Step 1: The engine speed is reduced Step 2: The superstructure drive is shut down Step 3: The engine is switched off – is started automatically Additional equipment The time interval between step 2 and step 3...
Page 718: Switching Units Of Measure
Crane operation 11.6 Settings and displays for crane operation Ending/ switching off Ending To end Economy Mode you can either: – press the accelerator pedal, – move a control lever, – switch on a power unit. Switching off • Select and confirm the symbol (2) – Symbol (1) is displayed.
Page 719: Setting The Characteristic Curves For The Control Levers
Crane operation 11.6 Settings and displays for crane operation 11.6.7 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 720: Using The Slewable Spotlights
Crane operation 11.6 Settings and displays for crane operation 11.6.8 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 721 Crane operation 11.6 Settings and displays for crane operation Manually swinging Turn upwards • Press the button (1) in at the top. Turn downwards • Push the button (1) down. The direction of the spotlights will be adjusted until you let go of the button or they reach their end position.
Page 722: Overriding Torque Reduction
Crane operation 11.6 Settings and displays for crane operation 11.6.9 Overriding 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 723: Displaying The Operating Hours
Crane operation 11.6 Settings and displays for crane operation 11.6.10 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 724 Crane operation 11.6 Settings and displays for crane operation Blank page 11 - 134 3 302 709 en Operating manual GMK5150L...
Page 725: Working Range Limiter
Crane operation 11.7 Working range limiter 11.7 Working range limiter You can set and monitor four different limits in the working range limiter menus: – A maximum overall height – A maximum working radius – A maximum slewing angle – A limited hoist rope travel The monitoring of the programmed limits can be switched on and off sepa- rately.
Page 726: Viewing Current Settings
Crane operation 11.7 Working range limiter 11.7.1 viewing current settings On the RCL dislay The displays show monitoring and speed limitations that are switched on. 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 727: Opening The Working Range Limiter Menu
Crane operation 11.7 Working range limiter In the CCS The RCL shows the limited working range for the Slewing angle and Working 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 728: Enter Limit Values - For The Overall Height
Crane operation 11.7 Working range limiter 11.7.3 Enter limit values – for the overall height – For unknown limit values, you can approach a shut-off point and accept the current overall height as Accept limit value. – If the limit values are known, you can Manually enter limit value. Danger of accident due to incorrectly set limit values! When entering the limit values, please note that movements can still take place even after switching off, which lead further into the shutdown range.
Page 729 Crane operation 11.7 Working range limiter Entering limit values manually • (A) – Select and confirm the display (1). • (B) – Enter the limit value, for example, 20.0 m and confirm the input. Display (1) shows the newly inputted limit value.
Page 730: Enter Limit Values - For The Working Radius
Crane operation 11.7 Working range limiter 11.7.4 Enter limit values – for the working radius – For unknown limit values, you can approach a shut-off point and accept the current working radius as Accept limit value. – If the limit values are known, you can Manually enter limit value. Danger of accident due to incorrectly set limit values! When entering the limit values, please note that movements can still take place even after switching off, which lead further into the shutdown range.
Page 731 Crane operation 11.7 Working range limiter Entering limit values manually • (A) – Select and confirm the display (1). • (B) – Enter the limit value, for example, 20.0 m and confirm the input. Display (1) shows the newly inputted limit value.
Page 732: Enter Limit Values - For The Slewing Range
Crane operation 11.7 Working range limiter 11.7.5 Enter limit values – for the slewing range – For unknown limit values, you can approach a shut-off point and accept the current slewing angle as Accept limit value. – If the limit values are known, you can Manually enter limit value. Danger of accident due to incorrectly set limit values! When entering the limit values, please note that movements can still take place even after switching off, which lead further into the shutdown range.
Page 733 Crane operation 11.7 Working range limiter Accepting limit value – Slewing angle A • Slew the main boom to the shutdown point from the right, for example, value (1). • Select and confirm the display (1). The value (1) will be accepted as the limit value (2), for example, +17.6°.
Page 734 Crane operation 11.7 Working range limiter Switch on monitoring • Select and confirm the symbol (1). The Slewing range monitoring is switched on. The movement towards the shutdown limit is continually reduced until reaching a standstill. The current limitation is displayed; à...
Page 735: Enter Limit Values - For The Hoist Rope Travel
Crane operation 11.7 Working range limiter 11.7.6 Enter limit values – for the hoist rope travel The limit values for the hoist rope travel can only be input by approaching the shutdown points. Manually inputting is not possible. Danger of accident due to incorrectly set limit values! When entering the limit values, please note that movements can still take place even after switching off, which lead further into the shutdown range.
Page 736 Crane operation 11.7 Working range limiter Risk of accidents due to the hoist rope travel limitation being switched off! Always set the telescope status and the boom position for crane operation first before setting limit values. In this way you prevent an interruption of crane operation due to shutdown. Entering the limit value for Raise •...
Page 737: Shutdown By Working Range Limiter
Crane operation 11.7 Working range limiter 11.7.7 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 738 Crane operation 11.7 Working range limiter Blank page 11 - 148 3 302 709 en Operating manual GMK5150L...
Page 739: Work Break
Crane operation 11.8 Work break 11.8 Work break 11.8.1 In case of short work breaks Risk of accident by 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 740: In Case Of Work Breaks Of More Than 8 Hours
Crane operation 11.8 Work break 11.8.2 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 741: Heating And Air-Conditioning System
Crane operation 11.9 Heating and air-conditioning system 11.9 Heating and air-conditioning system • Do not cover the grille (1). Air is sucked in through the grille. 11.9.1 Standard heating system • Switching on Start the engine. The heating output is only provided when the engine is running.
Page 742 Crane operation 11.9 Heating and air-conditioning system Air distribution You can direct the air to flow out of various air vents. • Select the corresponding symbol (1) for the desired air vents. A Top only B Top and bottom C Bottom only Adjusting the air vents 1 –...
Page 743: Air-Conditioning System
Crane operation 11.9 Heating and air-conditioning system 11.9.2 Air-conditioning system You can use the air-conditioning system to cool and dry the air in the crane cab. Notes 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 744 Crane operation 11.9 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 is red. • Set the desired temperature – symbol (2). •...
Page 745: Auxiliary Heater
Crane operation 11.9 Heating and air-conditioning system 11.9.3 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.
Page 746 Crane operation 11.9 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 747 Crane operation 11.9 Heating and air-conditioning system Switching heat- ing start on/off Switching on • Select a storage location (for example, #1) – symbol (1) red. You can also selected other storage locations. The auxiliary heating now starts at the times stored in the corresponding column.
Page 748: Cranestar System
Crane operation 11.10 CraneSTAR system 11.10 CraneSTAR system 11.10.1 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 749: Rigging Work
Rigging work 12.1 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. 11 - 1. 12.1 Rigging work checklists for crane operation with the main boom...
Page 750 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 4. For the free on wheels working position à – Check that the tyre pressure is correctly set; p. 1 - 18. – Check that the ground can support the maximum axle loads à...
Page 751 Rigging work 12.1 Rigging work checklists for crane operation with the main boom The following points only apply when rigging the truck crane on outriggers. To continue rigging in the Free on wheels working position, continue the checklist at point 12. 8.
Page 752 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 13. Earth the truck crane, if necessary; Earthing the truck crane , p. 12 - 15. 14. Inspect the truck crane, while looking out in particular for any leaking fluids (oil, fuel or water).
Page 753 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 19. Pick up the hook block and re-reeve the hoist rope, if necessary; à Hook block on a separate vehicle , p. 12 - 117, à Hook block on the bumper , p. 12 - 115, à...
Page 754 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 25. Enter and confirm the current rigging mode; Enter rigging mode , p. 11 - 32. 26. With the rigging mode adjusted accordingly, rig the counterweight combination required for the operation according to Lifting capacity à...
Page 755: Checklist: Unrigging
Rigging work 12.1 Rigging work checklists for crane operation with the main boom 12.1.2 CHECKLIST: Unrigging This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1.
Page 756 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 6. For on-road driving with a dolly: – Set down the superstructure on a dolly with the RCL adjusted accord- à ingly and switch on the boom floating position; p.
Page 757 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 11. Retract the step; p. 12 - 157. à CHECKLIST: Retracting the outriggers , 12. Retracting the outriggers; p. 12 - 43. 13. Switch on suspension (release locking) – symbol green (suspension à...
Page 758 Rigging work 12.1 Rigging work checklists for crane operation with the main boom Blank page 12 - 10 3 302 709 en Operating manual GMK5150L...
Page 759: Choice Of A Suitable Positioning Site
Rigging work 12.2 Choice of a suitable positioning site 12.2 Choice of a suitable positioning 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 760 Rigging work 12.2 Choice of a suitable positioning 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...
Page 761 Rigging work 12.2 Choice of a suitable positioning site Load-bearing area • Now calculate the required load-bearing area. à • Check that the surface of the outrigger pad ( p. 1 - 19) is larger than the calculated load-bearing area. If the surface of the outrigger pad is smaller, you will need to enlarge the load-bearing area.
Page 762: Safe Distance From Slopes And Pits
Rigging work 12.2 Choice of a suitable positioning site 12.2.2 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 763: Earthing The Truck Crane
Rigging work 12.2 Choice of a suitable positioning site 12.2.3 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 accident due to electric shock Earth the truck crane before you start to work with it –...
Page 764: Safe Distance From Overhead Power Lines
Rigging work 12.2 Choice of a suitable positioning site 12.2.4 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 accident due to electric shock The truck crane is not insulated.
Page 765 Rigging work 12.2 Choice of a suitable positioning 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 up to 110,000 V 3 m (9.8 ft) over 110,000 V up to 220,000 V 4 m (13.1 ft) over 220,000 V up to 380,000 V 5 m (16.4 ft)
Page 766 Rigging work 12.2 Choice of a suitable positioning site Blank page 12 - 18 3 302 709 en Operating manual GMK5150L...
Page 767: Rigging Work After Driving With A Dolly
Rigging work 12.3 Rigging work after driving with a dolly 12.3 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 768: Switching Off The Slewing Gear Freewheel
Rigging work 12.3 Rigging work after driving with a dolly 12.3.2 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 769: Switching Off Boom Pre-Tensioning
Rigging work 12.3 Rigging work after driving with a dolly 12.3.3 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 770 Rigging work 12.3 Rigging work after driving with a dolly Blank page 12 - 22 3 302 709 en Operating manual GMK5150L...
Page 771: Connecting/Disconnecting The Hand-Held Control
Rigging work 12.4 Connecting/disconnecting the hand-held control 12.4 Connecting/disconnecting the hand-held control For operation • Remove the hand-held control (1) from the clamp (2). For transport • Hang the hand-held control (1) in the clamp (2). • Close the covering (3). Operating manual 3 302 709 en 12 - 23...
Page 772 Rigging work 12.4 Connecting/disconnecting the hand-held control Functionality of the sockets The hand-held control is only active when it is connected to the sockets (1) or (2). Socket Enabled operations – Emergency operation for crane movements (except for telescoping mechanism) –...
Page 773 Rigging work 12.4 Connecting/disconnecting the hand-held control Connect the hand-held control • Open the cap (2) and remove the bridging plug (3) from the socket (1). • Insert the plug (5) into the socket (1) and secure it with the cap (2). •...
Page 774 Rigging work 12.4 Connecting/disconnecting the hand-held control Blank page 12 - 26 3 302 709 en Operating manual GMK5150L...
Page 775: Starting The Engine For Rigging
Rigging work 12.5 Starting the engine for rigging 12.5 Starting the engine for rigging For rigging work, you can start the engine: – With the hand-held control – From the control units of the outriggers. You can generally start the engine only if a bridging plug is inserted in all sockets not required.
Page 776 Rigging work 12.5 Starting the engine for rigging Starting All activities and inspections required to start the engine must be carried out à the engine before starting the engine; p. 4 - 1. • Wait until the lamps (1) and (2) light up. If the lamp (2) does not illuminate or flash after approx.
Page 777: Starting/Shutoff The Engine - From The Outrigger Control Units
Rigging work 12.5 Starting the engine for rigging 12.5.2 Starting/shutoff 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: – The ignition in the driver's cab must be switched on. –...
Page 778 Rigging work 12.5 Starting the engine for rigging Blank page 12 - 30 3 302 709 en Operating manual GMK5150L...
Page 779: Slewing Range - Only With The Standard Slewing Range Type
Rigging work 12.6 Slewing range – only with the Standard slewing range type 12.6 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 780: Enabled Outrigger Spans
Rigging work 12.6 Slewing range – only with the Standard slewing range type 12.6.2 Enabled outrigger spans Risk of overturning when slewing the superstructure With some outrigger spans, slewing is only permissible with certain à counterweight combinations and boom positions; Slewing with rigged counterweight , p.
Page 781: Outriggers - Overview - Maxbase Slewing Range Type
Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type 12.7 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 782 Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type Representation of the outrigger spans – Outrigger length The outrigger length ( I ) has a fixed value of 8.030 m (26.3 ft) and never changes. – Outrigger width All possible outrigger spans (1) to (5) are always shown for all outrigger beams.
Page 783: Representation In The Lifting Capacity Tables
Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type 12.7.2 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 8.030 m (26.3 ft). –...
Page 784: Enabled Outrigger Spans
Rigging work 12.7 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 785 Rigging work 12.7 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 3.800 m (12.5 ft)
Page 786 Rigging work 12.7 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 3.800 m (12.5 ft) 3.350 m (11.0 ft)
Page 787 Rigging work 12.7 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 released combinations.
Page 788 Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type Blank page 12 - 40 3 302 709 en Operating manual GMK5150L...
Page 789: Outrigger Operation
Rigging work 12.8 Outrigger operation 12.8 Outrigger operation Danger 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 790 Rigging work 12.8 Outrigger operation 5. Move the outrigger pads into the operating position and secure them; à p. 12 - 53. 6. Enlarge the load-bearing area if necessary; à Determining the required load-bearing area , p. 12 - 11, à...
Page 791: Checklist: Retracting The Outriggers
Rigging work 12.8 Outrigger operation 12.8.2 CHECKLIST: Retracting the outriggers This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! à 1. Retract the outrigger cylinders as far as possible; p.
Page 792: Preparing The Truck Crane
Rigging work 12.8 Outrigger operation 6. Switch off the engine; à – After operating it from the control units; p. 4 - 18. – After operating it from the crane cab or using the hand-held control; à p. 10 - 11. 12.8.3 Preparing the truck crane Driver's cab...
Page 793 Rigging work 12.8 Outrigger operation Switching the outrigger control units on/off You can switch the Outriggers control units on and off from the crane cab. The current status is displayed, either the symbol (1) or (2) grey. Switch the control units on: •...
Page 794: Setting The Outrigger Spans
Risk of accidents from incorrect or missing markings Replace missing and illegible markings. First query Manitowoc Crane Care for the correct position. This way you prevent the truck crane overturning due to an incorrect outrigger span.
Page 795 Rigging work 12.8 Outrigger operation Outrigger span (83%) Overall width 8.030 x 6.700 m (26.3 x 22.0 ft) Individual width 8.030 x 3.350 m (26.3 x 11.0 ft) (A) – Prerequisites Pins (1) and (2) must be pulled out (B) – Setting and securing •...
Page 796 Rigging work 12.8 Outrigger operation Outrigger span (50%) Overall width 8.030 x 5.100 m (26.3 x 16.7 ft) Individual width 8.030 x 2.550 m (26.3 x 8.4 ft) (A) – Prerequisites – Pin (1) must be removed – Pin (2) must be inserted (B) –...
Page 797: Extending/Retracting Outrigger Beams
Rigging work 12.8 Outrigger operation • For on-road Create the outrigger span 8.030 x 2.500 m (26.3 x 8.2 ft) for all outrigger driving beams and secure all the outrigger beams. à • Bring all the outrigger pads into driving position; p.
Page 798 Rigging work 12.8 Outrigger operation • Check that the pins are inserted/removed as specified in the prerequisites à for the desired outrigger span; p. 12 - 46. Depending on the rigging, control elements are provided for moving the outrigger beams à...
Page 799 Rigging work 12.8 Outrigger operation Retracting • 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. From the control units Starting the engine...
Page 800 Rigging work 12.8 Outrigger operation Moving the outrigger beams You can only operate the outrigger beams to the left and right of the control unit on the operator's side. • Observe the safety instructions for operating the outriggers; à p. 12 - 49. •...
Page 801: Moving The Outrigger Pads Into Operating/Driving Position
Rigging work 12.8 Outrigger operation 12.8.6 Moving the outrigger pads into operating/driving position Moving them into working position • (A) – Pull out the pin (1). • (B) – Pull the outrigger pad outwards by the handle (2). • Secure the outrigger pad with the pin (1). •...
Page 802 Rigging work 12.8 Outrigger operation Blank page 12 - 54 3 302 709 en Operating manual GMK5150L...
Page 803: Enlarging The Load-Bearing Area
Rigging work 12.8 Outrigger operation 12.8.7 Enlarging the load-bearing area If the surface of the outrigger pads is too small, you must enlarge the à Determining the load-bearing area by packing the outrigger pads; required load-bearing area , p. 12 - 11. For packing, use only suitable materials that will withstand the outrigger pressure, e.g.
Page 804: Extending/Retracting Supporting Cylinders
Rigging work 12.8 Outrigger operation 12.8.8 Extending/retracting supporting cylinders Danger of overturning due to insufficient load bearing capacity of the ground 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 805 Rigging work 12.8 Outrigger operation From the control units Starting the engine • Start the engine, either à – from the driver's cab; p. 4 - 13 à – from the control units; p. 12 - 27. Moving the supporting cylinders Assignment of buttons: 1 Supporting cylinder 1.1 2 Supporting cylinder 2.1...
Page 806 Rigging work 12.8 Outrigger operation From the The following operating elements are found in the Outrigger menu. crane cab Starting the engine à • Start the engine from the crane cab; p. 10 - 3. • Switch off the slewing gear. Menu, open •...
Page 807 Rigging work 12.8 Outrigger operation Retracting • 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 bottom – the selected supporting cylinder retracts. Operating manual 3 302 709 en 12 - 59...
Page 808: Levelling The Truck Crane On Outriggers Horizontally
Rigging work 12.8 Outrigger operation 12.8.9 Levelling the truck crane on outriggers horizontally You must level the truck crane before crane operation horizontally and possibly correct its horizontal alignment during crane operation. Inclination After switching on the ignition, various inclination indicators display the indicators current alignment.
Page 809 Rigging work 12.8 Outrigger operation – Outrigger control units The assignment to the carrier corresponds to the top view. Due to the position of the control units, the displays on both sides differ. In this example, the carrier would be stand- ing higher to the rear on the right hand side.
Page 810 Rigging work 12.8 Outrigger operation à • Manual alignment Check that the prerequisites are met; p. 12 - 61. • Extend all supporting cylinders until none of the wheels is touching the ground. • Level the truck crane with the supporting cylinders until the lamp (1) is the à...
Page 811 Rigging work 12.8 Outrigger operation • Extend the supporting cylinders until the outrigger pads are just above the ground. Starting procedure Depending on the truck crane's equipment, you can start the procedure from the hand-held control and the Outrigger control units. On the control units •...
Page 812: Levelling The Free-Standing Truck Crane
Rigging work 12.8 Outrigger operation 12.8.10 Levelling the free-standing truck crane This section describes the levelling with the outrigger. You can level the à truck crane using the axle raising; p. 12 - 66. The suspension is deactivated (locked) if the truck crane is in the Free on wheels working position.
Page 813 Rigging work 12.8 Outrigger operation Switching on the suspension • Select and confirm the symbol (1) once. The symbol (2) is green if the suspension is switched on. Now all wheels are lowered to the ground and are in the right position for the horizontal alignment.
Page 814: Operating The Axle Raising System
Rigging work 12.8 Outrigger operation 12.8.11 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 815 Rigging work 12.8 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 Operating manual 3 302 709 en 12 - 67 GMK5150L...
Page 816: Outrigger Pressure Display
Rigging work 12.8 Outrigger operation 12.8.12 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 817 Rigging work 12.8 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 Operating manual 3 302 709 en...
Page 818 Rigging work 12.8 Outrigger operation Blank page 12 - 70 3 302 709 en Operating manual GMK5150L...
Page 819: Rigging/Unrigging The Counterweight
Rigging work 12.9 Rigging/unrigging the counterweight 12.9 Rigging/unrigging the counterweight For driving, parts of the counterweight must be set down on the counter- weight platform, installed on the turntable or removed, depending on the à Driving modes , p. 6 - 1 driving mode;...
Page 820 Rigging work 12.9 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 821: Counterweight Sections
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.2 Counterweight sections Depending on the version, the GMK5150L can be equipped with a counter- weight mass of 1.0 t (2,205 lbs) or 44.5 t (98,106 lbs). There are various counterweight sections, depending on the truck crane's version and additional equipment.
Page 822 Rigging work 12.9 Rigging/unrigging the counterweight Version 3 This version enables you to drive with maximum axle loads of 12 t. Counterweight – one 1.0 t plate (1) or the auxiliary hoist (8), – one 2.3 t base plate (1), –...
Page 823: Identification
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.3 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 824: Slinging Points On The Counterweight Sections
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.4 Slinging points on the counterweight sections Risk of accident if used improperly Attach the lifting gear to various counterweight section only at the appro- priate slinging points. Ensure the lifting gear has sufficient load bearing capacity.
Page 825: Checklist: Rigging The Counterweight
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.5 CHECKLIST: Rigging the counterweight This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 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 826 Rigging work 12.9 Rigging/unrigging the counterweight 5. – Open Counterweight menu à – Correct the rigging mode, if necessary; p. 12 - 104, – Slew the superstructure into the rigging range and lift counterweight à to the turntable (automatic) and pre-charge; p.
Page 827: Checklist: Unrigging The Counterweight
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.6 CHECKLIST: Unrigging the counterweight This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! Danger of overturning when slewing with a rigged counterweight Before slewing with the rigged counterweight, check whether slewing is permissible with the rigged outrigger span or with the truck free on wheels;...
Page 828: Assembling Counterweight Combination
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.7 Assembling counterweight combination Danger of overturning when slewing with a rigged counterweight You may only slew the superstructure with a rigged counterweight if an outrigger span of sufficient size is rigged. You can find the required outrig- ger span in the table in the section titled Slewing with rigged counterweight , p.
Page 829 Rigging work 12.9 Rigging/unrigging the counterweight Setting down the 2.3 t base plate With versions 1, 2 and 3 Only the 2.3 t base plate may be set down directly on the counterweight platform. You can use the holder (3) to position the 2.3 t base plate centrally on the carrier.
Page 830 Rigging work 12.9 Rigging/unrigging the counterweight Version 1 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 82 3 302 709 en Operating manual...
Page 831 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight (10,142) (10,142) (5,071) (10,142) (5,071) (5,071) (2,205) (14,991) combina- (5,071) (5,071) tion in t (lbs) ● – – – – – – – – – (2,205) ● ●...
Page 832 Rigging work 12.9 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all coun- terweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 84 3 302 709 en Operating manual...
Page 833 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight (10,142) (10,142) (5,071) (10,142) (5,071) (5,071) (2,205) (14,991) combina- (5,071) (5,071) tion in t (lbs) ● ● ● ● – – – – – – ● ● ●...
Page 834 Rigging work 12.9 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 86 3 302 709 en Operating manual...
Page 835 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight (10,142) (10,142) (5,071) (10,142) (5,071) (5,071) (2,205) (14,991) combina- (5,071) (5,071) tion in t (lbs) ● ● ● ● – – – – – ● ● ● ●...
Page 836 Rigging work 12.9 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 88 3 302 709 en Operating manual...
Page 837 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight (10,142) (10,142) (5,071) (10,142) (5,071) (5,071) (2,205) (14,991) combina- (5,071) (5,071) tion in t (lbs) ● ● ● ● ● – – – – ● ● ● ●...
Page 838 Rigging work 12.9 Rigging/unrigging the counterweight Version 2 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 90 3 302 709 en Operating manual...
Page 839 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight (5,071) (5,071) (10,142) (5,071) (10,142) (20,283) (2,205) (14,991) combina- tion in t (lbs) ● – – – – – – – (2,205) ● ● – – – –...
Page 840 Rigging work 12.9 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 92 3 302 709 en Operating manual...
Page 841 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight (5,071) (5,071) (10,142) (5,071) (10,142) (20,283) (2,205) (14,991) combina- tion in t (lbs) ● ● ● ● ● – – – 19.4 ● ● ● ● (42,770) ●...
Page 842 Rigging work 12.9 Rigging/unrigging the counterweight Version 3 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 94 3 302 709 en Operating manual...
Page 843 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight (5,071) (5,071) (10,142) (10,142) (5,071) (5,071) (2,205) (14,991) combina- tion in t (lbs) ● – – – – – – – (2,205) ● ● – – – –...
Page 844 Rigging work 12.9 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 96 3 302 709 en Operating manual...
Page 845 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight 5,071 5,071 10,142 10,142 5,071 5,071 (2,205) (14,991) combi- nation in t (lbs) ● ● – – – – ● ● – – – – – ● ●...
Page 846 Rigging work 12.9 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 98 3 302 709 en Operating manual...
Page 847 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight 5,071 5,071 10,142 10,142 5,071 5,071 (2,205) (14,991) combi- nation in t (lbs) ● ● – – – – ● ● – – – – – ● ●...
Page 848 Rigging work 12.9 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. à • Slinging points on Lift the counterweight sections onto the base plate; the counterweight sections , p. 12 - 76. 12 - 100 3 302 709 en Operating manual...
Page 849 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight 5,071 5,071 10,142 10,142 5,071 5,071 (2,205) (14,991) combi- nation in t (lbs) ● ● ● – – – ● ● ● – – – ● ● ●...
Page 850: Counterweight Hoist Unit
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.8 Counterweight hoist unit The lifting cylinders (1) can be extended and retracted. To lift and lower the counterweight, the lifting cylinders are screwed into the 2.3 t base plate (2). Risk of crushing when lifting and lowering the counterweight! Make sure nobody is on the counterweight platform while the counter- weight is being lifted or lowered.
Page 851 1 Slewing blocked – pre-clamp the counter- à weight; p. 12 - 105. 2 Contact Manitowoc Crane Care 3 If the pre-tensioning pressure continues to drop, the message (1). Extending/retract- This section describes how to operate the lifting cylinders manually, ing the lifting –...
Page 852 Rigging work 12.9 Rigging/unrigging the counterweight Correct the rigging mode • You can use the automatic mode only if the current rigging mode is displayed. A Counterweight rigged B Counterweight unrigged If necessary, correct the displayed rigging mode as follows: •...
Page 853 Rigging work 12.9 Rigging/unrigging the counterweight Pre-tensioning When the symbol (5) is red, you must pre-ten- sion the counterweight. Slewing is blocked – symbol display (2). • Select and confirm the symbol (3) until the symbol (4) becomes green. The slewing is released –...
Page 854 Rigging work 12.9 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 855 Rigging work 12.9 Rigging/unrigging the counterweight Automatic mode While the automatic mode is being executed, you can always à unrigging – Cancel the automatic mode; Cancel automatic mode , p. 12 - 108. – Interrupt the automatic mode by letting go of the control lever. After moving the lever in the displayed direction once more, the automatic mode is continued.
Page 856 Rigging work 12.9 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 are retracted (D). • Release the control lever.
Page 857: Removing/Installing The Counterweight On The Turntable
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.9 Removing/installing the counterweight on the turntable Removing With version 1 and 3 two 2.3 t plates, with version 2 one 9.2 t plates can be removed/installed on the turntable. Version 1 and 3 •...
Page 858 Rigging work 12.9 Rigging/unrigging the counterweight Installing Version 1 and 3 • Use automatic mode to lift the counter- weight combination onto the turntable; à Automatic mode rigging , p. 12 - 105. • Push the clamp (2) through the bracket (3). •...
Page 859: Setting Down Counterweight For Driving
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.10 Setting down counterweight for driving Which parts of the counterweight sections can be transported on the turn- table and counterweight platform when driving the truck crane depends on à Driving modes , p. 6 - 1. the driving mode of the truck crane;...
Page 860 Rigging work 12.9 Rigging/unrigging the counterweight For driving with axle loads greater than 12 t – The 2.3 t plates (1) and (2) are mounted on the turntable, – The 2.3 t base plate (6) and the 2.3 t plate (5) lie on the counterweight platform, –...
Page 861: Slewing With Rigged Counterweight
Rigging work 12.9 Rigging/unrigging the counterweight Version 2 For driving with axle loads greater than 12 t – The 9.2 t plate (1) is mounted on the turntable, – The 2.3 t base plate (3) and the 2.3 t plate (4) lie on the counterweight platform.
Page 862 Rigging work 12.9 Rigging/unrigging the counterweight Blank page 12 - 114 3 302 709 en Operating manual GMK5150L...
Page 863: Rigging Work On The Main Boom
Rigging work 12.10 Rigging work on the main boom 12.10 Rigging work on the main boom 12.10.1 Hook block on the bumper à When the hook block is transported on a separate vehicle; p. 12 - 117. Picking up the Depending on the driving mode, you must pick up the hook block from the à...
Page 864 Rigging work 12.10 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 865: Hook Block On A Separate Vehicle
Rigging work 12.10 Rigging work on the main boom 12.10.2 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 866 Rigging work 12.10 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 867 Rigging work 12.10 Rigging work on the main boom • Detach the lifting limit switch weight (2) à from the hoist rope; p. 12 - 142. à • Unreeve the hoist rope; p. 12 - 131. • Secure the hook block (1) for transport. •...
Page 868: Hook Block, Separable
Rigging work 12.10 Rigging work on the main boom 12.10.3 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 869 Rigging work 12.10 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 870: Hook Block With Ballast Plates
Rigging work 12.10 Rigging work on the main boom 12.10.4 Hook block with ballast plates There are 1 and 3-sheave hook blocks for both versions A and B. By removing and installing ballast plates, you can adapt the hook block weight to the weight required according to the Lifting capacity table .
Page 871 Rigging work 12.10 Rigging work on the main boom Installing Risk of accident due to falling ballast plates. Always secure the ballast plates with the pins and the securing plugs. Always check the completeness and condition of the securing plugs before operating the crane.
Page 872: Reeving And Unreeving The Hoist Rope
Rigging work 12.10 Rigging work on the main boom 12.10.5 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, à Possible reevings on the main boom , p.
Page 873 Rigging work 12.10 Rigging work on the main boom Positioning • Plug the holder (3) and slide it onto the hoist rope as far as it will go (4). • Fasten the fork (1) using the pin (2). • Secure the pin. Version B Removing •...
Page 874 Rigging work 12.10 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 875 Rigging work 12.10 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 - 48. Danger due to slack rope! Only use hook blocks and lifting gear of the minimum weight prescribed in the Lifting capacity table , depending on the reeving and boom length.
Page 876 Rigging work 12.10 Rigging work on the main boom For hook blocks with ballast plates, you can achieve the required weight by installing or à removing ballast plates; p. 12 - 122. Opening the hook block • Pull out the rods (2). •...
Page 877 Rigging work 12.10 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 878 Rigging work 12.10 Rigging work on the main boom – Rope end fitting • Fasten the rope end fitting (3) using the pin (2). (A) – If there is an even number of lines to a fixed point (1) of the main boom head. (B) –...
Page 879 Rigging work 12.10 Rigging work on the main boom Unreeving hoist rope • Pull out the rods (5) and (3). • Fold down the plates (1). • Remove the rope end fitting from the fixed point (2) or (4). • Unreeve the hoist rope.
Page 880: Possible Reevings On The Main Boom
Rigging work 12.10 Rigging work on the main boom 12.10.6 Possible reevings on the main boom Possible reevings on lattice extensions and the auxiliary single-sheave à Lattice extension operating manual. boom top; The maximum lifting capacity is specified in the supplied lifting capacity table . à...
Page 881 Rigging work 12.10 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 manual 3 302 709 en 12 - 133 GMK5150L...
Page 882 Rigging work 12.10 Rigging work on the main boom 1-sheave hook block Reeving 3-fall 2-fall 1-fall Hook tackle Reeving 1-fall 12 - 134 3 302 709 en Operating manual GMK5150L...
Page 883 Rigging work 12.10 Rigging work on the main boom With 8 head With additional equipment, 8 head sheaves may be present. à sheaves If 6 head sheaves are provided; p. 12 - 132. 8-sheave hook block Reeving 16-fall 7-sheave hook block Reeving 15-fall 14-fall...
Page 884 Rigging work 12.10 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 12 - 136 3 302 709 en Operating manual GMK5150L...
Page 885 Rigging work 12.10 Rigging work on the main boom 1-sheave hook block Reeving 3-fall 2-fall 1-fall Hook tackle Reeving 1-fall Operating manual 3 302 709 en 12 - 137 GMK5150L...
Page 886 Rigging work 12.10 Rigging work on the main boom With 9 head The 7th head sheave of the auxiliary single-sheave boom top is used for sheaves this version. 9-pulley hook block Reeving 18-falls Additional equipment; à Lattice extension operating manual à...
Page 887: Installing/Removing The Lifting Limit Switch
Rigging work 12.10 Rigging work on the main boom 12.10.7 Installing/removing the lifting limit switch à Function of the lifting limit switch; p. 11 - 82. 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 888 Rigging work 12.10 Rigging work on the main boom If only one lifting limit switch has been installed • Cover the unused socket with the protective cap (2). • Check whether the lock on the used lifting limit switch, e.g. (1), is released; à...
Page 889 Rigging work 12.10 Rigging work on the main boom Attaching the lifting limit switch weight • Attach the lifting limit switch weight (1). These lifting limit switches must not be à Removing the lock , p. 12 - 144. blocked; If two hoist ropes are reeved, you must attach a lifting limit switch weight to each of the two lifting limit switches.
Page 890 Rigging work 12.10 Rigging work on the main boom Removing the lift- This section describes complete removal. ing limit switch If the hook block is to be attached to the bumper at a later point, you will need to detach the lifting limit switch weight from the hoist rope, so that you can unreeve or reeve when unrigging the hoist rope.
Page 891 Rigging work 12.10 Rigging work on the main boom Removing the right lifting limit switch • Pull out the plug and close the socket with the protective cap (1). • Remove the lifting limit switch (4) from the bracket (2) •...
Page 892: Locking/Unlocking The Lifting Limit Switch
Rigging work 12.10 Rigging work on the main boom 12.10.8 Locking/unlocking the lifting limit switch Locking If two lifting limit switches are installed, you must lock the lifting limit switch not used in order to enable all crane operations. Risk of damage if the lifting limit switch is locked If the lifting limit switch on which the lifting limit switch weight hangs is locked, release the lock.
Page 893: Anemometer And Air Traffic Control Light
Rigging work 12.10 Rigging work on the main boom 12.10.9 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 894 Rigging work 12.10 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 895 Rigging work 12.10 Rigging work on the main boom Removing You must remove the rod with the anemometer/air traffic control light before driving on the road. • Switch off the air traffic control light. • Remove the plug and close the sockets (5) and (4) with the protective caps.
Page 896 Rigging work 12.10 Rigging work on the main boom Blank page 12 - 148 3 302 709 en Operating manual GMK5150L...
Page 897: Other Rigging Work
Rigging work 12.11 Other rigging work 12.11 Other rigging work 12.11.1 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 stepping on to the turntable.
Page 898: Folding The Mirrors In And Out, And Adjusting Them
Rigging work 12.11 Other rigging work 12.11.2 Folding the mirrors in and out, and adjusting them The mirror must be folded in for driving. You must fold the mirror out and adjust it for crane operation or driving from the superstructure. Risk of accidents due to exceeding the permissible dimensions! Fold the mirror in for driving.
Page 899: Slinging Points For Personal Protective Equipment
Rigging work 12.11 Other rigging work 12.11.3 Slinging points for personal protective equipment The labels (2) mark the approved slinging points for personal safety equipment, for example, slinging point (1). The slinging options (3) and (4) are provided for the attachement of a fall protection device. •...
Page 900: Cameras For Crane Operation
Rigging work 12.11 Other rigging work 12.11.4 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 transmitter (1) and the associated receiver (2) are matched to each other and are identified by the same number on the...
Page 901 Rigging work 12.11 Other rigging work You will need the respective connecting cable to connect the camera to a lat- tice extension. This means certain pre-conditions are applicable to installa- tion and removal. Risk of accidents due to falling camera Always use a retaining pin to hold the camera in the clamp.
Page 902 Rigging work 12.11 Other rigging work Removing – Only the camera • Withdraw the plug (4) from the socket (3) and close it with the cap. • Remove the camera (2) from the clamp (1) and put the retaining pin in the holder (1). •...
Page 903 Rigging work 12.11 Other rigging work Camera on This section describes the CCS display as the monitor. Depending on the 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 904 Rigging work 12.11 Other rigging work Operating Depending on the version, the image is shown on the CCS display or on a the camera separate monitor. Switching on • Switch on the ignition. • (A) – Select and confirm the symbol (1) •...
Page 905: Step At The Crane Cab
Rigging work 12.11 Other rigging work 12.11.5 Step at the crane cab You can operate the step in the Crane cab menu or on the outrigger control unit. Risk of accidents by exceeding the permissible overall width! Always retract the step for on-road driving. When the step is extended, the overall width specified for on-road driving is exceeded.
Page 906 Rigging work 12.11 Other rigging work Blank page 12 - 158 3 302 709 en Operating manual GMK5150L...
Page 907: Driving With A Rigged Truck Crane
Driving with a rigged truck crane 13.1 Route Driving with a rigged truck crane This section describes driving the truck crane with the counterweight à Lattice extension operating rigged. If a lattice extension is also rigged; manual . 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, for example, the raised main boom in the 0°...
Page 908 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads 13.2 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 909 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads Counter Telescope status Main boom Superstruc- Axle load I - II - III - IV - V weight Angle ture position in t (x 1,000 lbs) in t in °...
Page 910 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads Blank page 13 - 4 3 302 709 en Operating manual GMK5150L...
Page 911: To Drive Without A Load
Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads 13.2.1 To drive without a load • Bring the main boom to an inclination permitted within the working range. • Tie down the hook block so that it cannot swing around. 13.2.2 To drive with a load When the truck crane is being driven with a lifted load, it may be driven only...
Page 912: Axle Loads
Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads 13.2.3 Axle loads The axle loads do not exceed 25.0 t (55,116 lbs) if the main boom is within the permissible working range in a permissible Lifting capacity table Free-on-wheels working position.
Page 913: Before Driving The Rigged Truck Crane
Driving with a rigged truck crane 13.3 Before driving the rigged truck crane 13.3 Before driving the rigged truck crane 13.3.1 Check the tyre pressures and wind speed • Ensure that all the tyres are at the prescribed pressure levels; à...
Page 914: Putting The Truck Crane On The Wheels - With Raise Axle Function
Driving with a rigged truck crane 13.3 Before driving the rigged truck crane • Switch off the slewing gear – The lamp in the button (1) must be dimly lit. – Then symbol (2) turns red – slewing gear switched off. –...
Page 915 Driving with a rigged truck crane 13.3 Before driving the rigged truck crane 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.
Page 916: Putting The Truck Crane On The Wheels - With The Outriggers
Driving with a rigged truck crane 13.3 Before driving the rigged truck crane 13.3.4 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...
Page 917 Driving with a rigged truck crane 13.3 Before driving the rigged truck crane 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. •...
Page 918 Driving with a rigged truck crane 13.3 Before driving the rigged truck crane Blank page 13 - 12 3 302 709 en Operating manual GMK5150L...
Page 919: Driving From The Driver's Cab
Driving with a rigged truck crane 13.4 Driving from the driver's cab 13.4 Driving from the driver's cab Risk of accidents when driving the truck crane from the driver's cab with a lifted load! With a lifted load, drive the truck crane only from the crane cab. You must be able to carry out crane movements in an emergency at all times.
Page 920: Whilst Driving
Driving with a rigged truck crane 13.4 Driving from the driver's cab 13.4.2 Whilst driving • Only drive slowly, do not change up. • 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.
Page 921: After Driving
Driving with a rigged truck crane 13.4 Driving from the driver's cab 13.4.3 After driving à • Switch separate steering off after driving; p. 5 - 63. • Engage 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 touches the ground.
Page 922 Driving with a rigged truck crane 13.4 Driving from the driver's cab Blank page 13 - 16 3 302 709 en Operating manual GMK5150L...
Page 923: Driving From The Crane Cab
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5 Driving from the crane cab Risk of accidents when driving with a lifted load The truck crane may be driven with a lifted load only when it is in the Free on wheels working position and the current rigging mode has been entered and confirmed on the RCL.
Page 924: Preparing To Drive
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.1 Preparing to drive • Make sure that the rigging mode for driving with a load or without a load à is set correctly; p. 13 - 2. In the driver's cab –...
Page 925: Opening/Closing The Driving Menu
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.2 Opening/closing the driving menu Opening the menu • Select and confirm the symbol (1). The menu opens automatically the first time you release the parking brake after switching on the ignition. The display will show (A) or (B) depending on the current slewing angle;...
Page 926 Driving with a rigged truck crane 13.5 Driving from the crane cab In crane operation The symbol (2) is white. The gear indicator (1) indicates gear 15 (shift position for supplying the crane's hydraulic system). The operating elements (3) are disabled. The buttons (4) are assigned the High-speed function.
Page 927 Driving with a rigged truck crane 13.5 Driving from the crane cab Crane's hydraulic In driving mode, the crane's hydraulic system is driven by a different energy system Driving source from the one used in crane operation. mode The switchover is automatic, and the current status is displayed. 1 Arrow orange –...
Page 928: Steering
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.3 Steering Switching on Switching over to Driving mode switches on the normal steering mode. Display and The display of the carrier depends on the current slewing angle; Carrier display , p.
Page 929 Driving with a rigged truck crane 13.5 Driving from the crane cab Switching the The steering direction switched on is saved and is retained even after a steering direction restart. The display shows the currently set steering direction. 1 Steering direction Steering wheel 2 Steering direction Reversed (compared to steering wheel) Switching over •...
Page 930 3. to 5th axle line automatically steered The symbol (4) indicates the selected steering mode, for example, Driving around corners . à If the error symbol is displayed, contact p. 8 - 24. Manitowoc Crane Care 13 - 24 3 302 709 en Operating manual GMK5150L...
Page 931 Driving with a rigged truck crane 13.5 Driving from the crane cab Steering with separate steering – automatic The symbol (2) or (3) is displayed for the desired steering mode. • Steer the 1st and 2nd axle lines with the button (1). •...
Page 932 Driving with a rigged truck crane 13.5 Driving from the crane cab Steering with separate steering – manual The (3) symbol is displayed • Steer the 1st and 2nd axle lines with the button (1). • Steer the 3rd to 5th axle lines with the button (2). •...
Page 933 Select and confirm the symbol (3) – display symbol (4). à If the error symbol is displayed, contact p. 8 - 24. Manitowoc Crane Care Steering in normal steering mode The (2) symbol is displayed. • Steer the 1st and 2nd axle lines with the button (1).
Page 934: Operating The Transmission
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.4 Operating the transmission When the Driving operating mode is switched on, the transmission is in neutral position – letter N (1) white. Selecting the You can select transmission modes with crane functions and transmission transmission modes without crane functions.
Page 935: Whilst Driving
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.5 Whilst driving DM and RM trans- The truck crane drives in 1st gear only, and the transmission does not shift. mission mode Risk of accidents when driving with a lifted load The maximum permissible speed for driving with a lifted load is 1.5 km/h (1 mph).
Page 936: Possible Connections
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.6 Possible connections Risk of damage to the differential locks Leave the transverse differential locks switched on only for as long as necessary. Always switch off the transverse differential locks before driving on a firm surface You can make the following connections, one after the other:...
Page 937 – first symbol (2) – yellow, then symbol (3) – green, differential locks off. If symbol (3) is not green then drive back and forth slowly. If the error symbol is displayed, contact Manitowoc Crane Care Operating manual 3 302 709 en 13 - 31 GMK5150L...
Page 938: After Driving
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.7 After driving • Bring the truck crane to a halt with the brake pedal (1). • Restore the original condition: – Switch the transmission to neutral position (1) –...
Page 939: 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 940: What To Do When Malfunctions Occur During Crane Operation
• Inform your supervisor. • Try to eliminate the malfunction. Inform if you Manitowoc Crane Care cannot correct the malfunction. • Load cannot Secure the danger area using cordons and warning signs. be set down •...
Page 941: 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 942 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 943 Switch off the engine immediately and open the Engine error menu; à p. 8 - 17. • If necessary, note the error messages and contact Manitowoc Crane Care Refuelling The fuel tank is filled only to a level of about 5%. à •...
Page 944 Malfunctions during crane operation 14.3 Warning and error messages Air intake inhibitor triggered It is only possible to start the engine after the air intake inhibitor has been à Opening the air intake inhibitor , p. 4 - 20. released manually; Pre-tension counterweight (early warning) The pre-tensioning pressure is at the lower limit –...
Page 945 – If the sybol is still displayed, then start the engine from the cab and carry out a few gear changes in the transmission. – If the symbol continues to be displayed, please contact Manitowoc Crane Care Emergency stop switch actuated à...
Page 946: 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 qualified personnel. •...
Page 947 • Select and confirm symbol (1) to acknowledge the error. If the error cannot be acknowledged, consult Manitowoc Crane Care. Error message display For each error the display shows: – The error code (5) – The symbols for 1 the faulty component...
Page 948: 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 (2) and (3) light up. A symbol is displayed, e.g. the symbol (1). If several warning messages are pending, all of the corresponding symbols are displayed one after the other in consecutive order.
Page 949 Malfunctions during crane operation 14.3 Warning and error messages – Lattice extension angle too small à Raise the lattice extension; Lattice extension operating manual . – Lattice extension angle too large à Lower the lattice extension; Lattice extension operating manual . –...
Page 950 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 951 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 952 Malfunctions during crane operation 14.3 Warning and error messages Blank page 14 - 14 3 302 709 en Operating manual GMK5150L...
Page 953: Troubleshooting
Control unit faulty, error Acknowledge error message à message is displayed once; p. 14 - 8 – if error persists, notify Manitowoc Crane Care Only the lifting function Lowering limit switch Leave the shutdown range works approached and raise the hoist.
Page 954 If required, acknowledge high-speed mode error message once and function not working briefly turn off the ignition – it if occurs again, notify Manitowoc Crane Care No lift function Control unit fuse blown Replace the blown fuse; à p. 14 - 75 à...
Page 955: Malfunctions In The Hoist Cameras
Check fuses and replace as à Manufacturer necessary; operating instructions . Connection between camera Check cable connection and and monitor is disconnected. notify Manitowoc Crane Care if necessary. Extendable tripod Fuse F7/5 blown Replace blown fuse; à not working p. 14 - 75. 14.4.4...
Page 956: Malfunctions On The Derricking Gear
Control unit faulty, error mes- Acknowledge error mes- à sage is displayed sage once; p. 14 - 8 – 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...
Page 957: Malfunctions In The Telescoping Mechanism
Control unit faulty, error Acknowledge error mes- à message is displayed sage once; p. 14 - 8 – if error persists, notify Manitowoc Crane Care Extending function not Control unit fuse blown Replace the blown fuse; à working p. 14 - 75 RCL shutdown, lamp lights Leave the shutdown range;...
Page 958: Malfunctions On The Slewing Gear
à blocked p. 14 - 33 The main boom can no The hydraulic supply is Inform Manitowoc Crane Care longer be telescoped; the interrupted telescoping cylinder can no longer be moved No response to control CCS malfunction for operat- Unrig using hand-held à...
Page 959 Malfunctions during crane operation 14.4 Troubleshooting Malfunction Cause Solution Slewing only possible in Shutdown angle of a limited Enter the RCL code for a one direction slewing range reached slewing range of 360° ( Standard ) or reduce the (additional equipment). working radius ( MAXbase ) or slew in the opposite direction to leave the...
Page 960: Malfunctions On The Counterweight Hoist Unit
Electronic system has briefly turn off the ignition – detected an electrical or it if occurs again, notify logical error Manitowoc Crane Care à Extend lifting cylinder Superstructure unlocked Lock the superstructure , not working p. 11 - 16 14.4.9...
Page 961: Malfunctions When Operating With The Hand-Held Control
Another function has been Pre-select the desired not be performed pre-selected function Operation not possible Malfunction in the control Inform Manitowoc Crane Care system 14.4.11 Malfunctions when inclining the crane cab Malfunction Cause Solution Crane cab inclination function Control unit fuse blown Replace the blown fuse;...
Page 962: Malfunctions Of The Outriggers
à ture or a bridging plug not p. 12 - 25 inserted None of the specified Solenoid valves are not Inform Manitowoc Crane Care causes apply switching electrically 14.4.14 Malfunctions on the turntable lock Malfunction Cause Solution...
Page 963: Malfunctions On The Ccs/Rcl Control Units
– it if occurs again, notify Manitowoc Crane Care If this table does not help to remedy the malfunction; à Malfunctions in the transmission , p. 8 - 23, à...
Page 964: Malfunctions On The Cranestar System
Malfunctions during crane operation 14.4 Troubleshooting 14.4.17 Malfunctions on the CraneSTAR system If an error is present, then check the fuses and the electronic connections. Risk of damage if procedure is incorrect Observe the following notes to avoid malfunctions and damage. –...
Page 965 Malfunctions during crane operation 14.4 Troubleshooting • Check the fuses (1) and replace them if necessary. Designation Amperage F3401 F3402 • Check whether the plugs (2) are plugged in: After checking • Fold the plate (3) up and secure it with the screws (4).
Page 966 Malfunctions during crane operation 14.4 Troubleshooting Blank page 14 - 28 3 302 709 en Operating manual GMK5150L...
Page 967: 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 menu –...
Page 968: 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 - 30 3 302 709 en...
Page 969 Malfunctions during crane operation 14.5 Emergency operations and programs Mechanical The following requirements must be met before manually unlocking a lock: emergency – The main boom must be lowered to the horizontal position so that the activation telescopic section cannot retract by itself. –...
Page 970 Malfunctions during crane operation 14.5 Emergency operations and programs Unlocking lock • (A) – Extend about 35 mm (0.11 ft), so that the cutout (4) is accessible. • (B) – Screw a bolt into the bore (1). The lock- ing pins (2) must retract behind the tele- scopic section (3).
Page 971: Telescoping Emergency Program
Malfunctions during crane operation 14.5 Emergency operations and programs 14.5.2 Telescoping emergency program The emergency program is intended only for retracting the telescoping when operation with the teleautomation menus is no longer possible due to a malfunction. The emergency program is enabled only when the current locking status can still be detected by the crane control.
Page 972 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 973 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 974 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 975 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 unlocked –...
Page 976 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 977 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 978 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 about 25 mm further than for a return run.
Page 979: 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 980 Malfunctions during crane operation 14.5 Emergency operations and programs You can cancel the entry at any time using the (1) or (2) buttons. 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 981: 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 982 Malfunctions during crane operation 14.5 Emergency operations and programs To pre-select a The preselection is the same for all power units except the telescoping power unit mechanism. • Press the corresponding button once, e.g. button (1) for the main hoist. The lamp in the button illuminates –...
Page 983 Malfunctions during crane operation 14.5 Emergency operations and programs Pre-selected power unit Telescoping Derricking Slewing Lattice Button Hoist mechanism gear gear extension combination Lock Lower Lowering Lower turntable Unlock turn- Retract Raise Lifting Raise table Slew to right Slew to left Stopping The movement continues until you release the button or the end position is movements...
Page 984: 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 14 - 46 3 302 709 en Operating manual...
Page 985 Malfunctions during crane operation 14.5 Emergency operations and programs Rigged outrigger span 8.030 x (26.3 x) 100% 2.500 m 5.100 m 5.900 m 6.700 m 7.600 m Free on (8.2 ft) (16.7 ft) (19.4 ft) (22.0 ft) 24.9 ft) wheels 1.0 t (2,205 lbs) 3.3 t...
Page 986 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 987: Rotate For Overridden Slewing Gear Shutdown
Malfunctions during crane operation 14.5 Emergency operations and programs 14.5.6 Rotate for overridden slewing gear shutdown If the slewing gear is not switched off due to the load torque, turning can be released within the permissible operating range. For example, for emer- gency unrigging when the counterweight cannot be fully pre-stressed.
Page 988 Malfunctions during crane operation 14.5 Emergency operations and programs Blank page 14 - 50 3 302 709 en Operating manual GMK5150L...
Page 989: Hydraulic Emergency Operation With The Hand Pump
Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump 14.6 Hydraulic emergency operation with the hand pump This section only applies to the standard hydraulic emergency operation. With the appropriate equipment you can also use the hydraulic emergency à...
Page 990: Switching Over The Crane's Hydraulic System
Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump 14.6.2 Switching over the crane's hydraulic system If you wish to move the hoist during emergency operation, you can open tap 4 at the beginning of the operation – as described in this section – this leads to the elimination of this step later during emergency operation.
Page 991: Establishing The Hydraulic Circuits Required
Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump 14.6.3 Establishing the hydraulic circuits required You must switch over the necessary valves to establish a hydraulic circuit. The valves 1 to 3 are secured against unintentional switching over. Releasing/ Releasing/securing is described for a valve.
Page 992 Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump Switching The valves 1 to 3 are labelled with their respective numbers. over valves For crane operation • Switch the valves (1), (2) and (3) forwards – valves closed. •...
Page 993 Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump For lowering You must additionally switch a valve to continuous operation for lowering. Switching on continuous operation • Unscrew the cap (2) from valve Y1104 – Lowering (1). •...
Page 994: Performing Emergency Activation
Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump 14.6.4 Performing emergency activation If the required hydraulic circuit has been established, you can make the corresponding crane movement using the hand pump (1). • Insert the pump lever (2) provided into the holder at the hand pump lever.
Page 995: After Emergency Activation
Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump 14.6.5 After emergency activation You must restore the truck crane to its original state after finishing emergency activation. After each emergency activation à • Switch valves 1 to 3 to crane operation; p.
Page 996 Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump Blank page 14 - 58 3 302 709 en Operating manual GMK5150L...
Page 997: Applications And Function
Malfunctions during crane operation 14.7 Hydraulic emergency operation acc. to BGR 159 14.7 Hydraulic emergency operation acc. to BGR 159 This section only only applies to hydraulic emergency operation in acc. with BGR 159. Optionally you can also use the emergency operation with the à...
Page 998 Malfunctions during crane operation 14.7 Hydraulic emergency operation acc. to BGR 159 Emergency supply You can supply another crane that also has an hydraulic emergency operation according to BGR 159. In the event of emergency supply, the connec- tions (1) feed a transformer (2) which is con- nected to the hydraulic system of the other crane.
Page 999: Checklist: Emergency Operation
Malfunctions during crane operation 14.7 Hydraulic emergency operation acc. to BGR 159 14.7.2 CHECKLIST: Emergency operation This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1.
Page 1000: Checklist: After Emergency Operation
Malfunctions during crane operation 14.7 Hydraulic emergency operation acc. to BGR 159 14.7.3 CHECKLIST: After emergency operation This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1.

Manitowoc GROVE GMK5150L Operating Manual

Overview

Accidents

Branch Offices

Warranty Specifications

Terms Used

Technical Data

Documentation Supplied

Notes on the Operating Manual

Conversion Table for US Measuring Units

Training - Information

Identification

EC Declaration of Conformity

Quick Links

Troubleshooting

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Summary of Contents for Manitowoc GROVE GMK5150L