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Manitowoc GROVE GMK5150XL Operating Manual

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Operating manual

3 303 279 en

23.03.2022

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Summary of Contents for Manitowoc GROVE GMK5150XL

Page 1 Operating manual 3 303 279 en 23.03.2022...
Page 2: Important Note
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 Transmission Power driving mode In addition to what is described in the supplied Operating manual, you can select the Power driving mode in automatic operating mode. In this driving mode, the transmission only shifts to the next gear at higher engine speeds. Fuel consumption increases.
Page 4 Blank page 3 303 233 en Additional page GMK...
Page 5 Fuses in the crane cab Modifications The configuration and arrangement of the fuses in the crane cab can deviate from the specifications in the provided operating manual depending on the version of the truck crane. Version (A) There is an overview (2) on the back of the cover (1).
Page 6 Diagnostic connection The diagnostic connection (1) may only be operated by the service personnel. The diagnostic connection (1) is located in the console at the top right of the crane cab. 3 303 238 en Additional page GMK...
Page 7 The operating manual has the following chapters: 1 Overview 2 Basic safety instructions 3 Operating elements for driving 4 Starting the engine / switching it off – for driving 5 Driving mode 6 Driving modes / rigging for on-road driving 7 Transport 8 Malfunctions in driving mode 9 Operating elements for crane operation...
Page 8 Blank page 3 303 279 en Operating manual GMK5150XL...
Page 9 Operating manual 3 303 279 en GMK5150XL...
Page 10 3 303 279 en Operating manual GMK5150XL...
Page 11: Table Of Contents
Overview General instructions ..........1 - Accidents .
Page 12 3 303 279 en Operating manual GMK5150XL...
Page 13: Basic Safety Instructions
Basic safety instructions Observe the safety manual ..........2 - Intended use .
Page 14 3 303 279 en Operating manual GMK5150XL...
Page 15 Operating elements for driving Overview – Notes........... . 3 - Overview –...
Page 16 3.5.12 BirdView system 270° ..........3 - 64 3.5.13 Transfer case .
Page 17 Starting the engine / switching it off – for driving Starting the engine from the driver's cab ....... . 4 - 4.1.1 CHECKLIST: Starting the engine .
Page 18 3 303 279 en Operating manual GMK5150XL...
Page 19 Driving mode Before driving ............5 - 5.1.1 CHECKLIST: Checks before on-road driving .
Page 20 Separate steering........... 5 - 79 5.5.1 Switching to separate steering .
Page 21 Driving modes / rigging for on-road driving Driving modes ............6 - 6.1.1 Information on how to use the tables .
Page 22 3 303 279 en Operating manual GMK5150XL...
Page 23 Transport Transport with transport vehicle ........7 - 7.1.1 CHECKLIST: Checks before transport .
Page 24 3 303 279 en Operating manual GMK5150XL...
Page 25 Malfunctions in driving mode Emergency stop switches ..........8 - What to do in the event of malfunctions .
Page 26 3 303 279 en Operating manual GMK5150XL...
Page 27 Operating elements for crane operation Overview – Notes........... . 9 - Overview –...
Page 28 9.5.8 CCS crane control ..........9 - 103 9.5.9 Outrigger –...
Page 29 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 30 3 303 279 en Operating manual GMK5150XL...
Page 31 Crane operation 11.1 Before operating the crane ......... . . 11 - 11.1.1 CHECKLIST: Checks before crane operation .
Page 32 11.5.6 Telescoping mechanism ..........11 - 91 11.5.7 High-speed mode .
Page 33 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 34 12.7.4 Slinging points ........... 12 - 71 12.7.5 CHECKLIST: Rigging the counterweight .
Page 35 Driving with a rigged truck crane 13.1 Driving distance........... . 13 - 13.2 Permissible rigging modes and axle loads .
Page 36 3 303 279 en Operating manual GMK5150XL...
Page 37 Malfunctions during crane operation 14.1 Emergency stop switch..........14 - 14.2 What to do when malfunctions occur during crane operation .
Page 38 14.7 Hydraulic emergency operation according to DGUV ..... 14 - 61 14.7.1 Applications and functionality ........14 - 61 14.7.2 CHECKLIST: Emergency operation .
Page 39 Index Operating manual 3 303 279 en GMK5150XL...
Page 40 3 303 279 en Operating manual GMK5150XL...
Page 41: Overview
1 Overview 1.1 General instructions Overview General instructions This operating manual contains illustrations of the GMK5150L-1 with five telescopic sections. The GMK5150XL has six telescopic sections (1). The illustrations have only been modified where relevant for operation. Accidents In case of an accident, contact the relevant branch of Grove Product Support in the country in which you are working and state your crane type and serial number.
Page 42 1 Overview 1.2 Accidents Blank page 1 - 2 3 303 279 en Operating manual GMK5150XL...
Page 43: Branch Offices
1 Overview 1.3 Branch offices Branch offices If you need help or support with the operation of your truck crane, you can contact our branches at the following addresses Grove Product Support http://www.manitowoccranes.com You can also scan the following QR code. 1.3.1 Dealer list A global list of dealers is provided at the following address:...
Page 44: Terms Used
1 Overview 1.5 Terms used Terms used 1 - 4 3 303 279 en Operating manual GMK5150XL...
Page 45 1 Overview 1.5 Terms used (A) – Carrier 1 Driver's cab 2 Boom rest 3 Counterweight platform 4 Axle lines 5 Outrigger beams 6 Outrigger cylinders 7 Outrigger pads (B) – Superstructure 8 Crane cab 9 Main boom with telescoping mechanism 10 Telescopic sections 11 Hook block 12 Derricking cylinder, derricking gear...
Page 46 1 Overview 1.5 Terms used Blank page 1 - 6 3 303 279 en Operating manual GMK5150XL...
Page 47: Technical Data
1 Overview 1.6 Technical data Technical data GROVE crane GMK5150XL Permissible temperature range: -25 °C to +40 °C (-13 °F to +104 °F) Crane designation: Mobile crane as per DIN 15 001, Part 1 Crane application: Truck crane as per DIN 15 001, Part 2 Crane classification: Hoist class H1 as per DIN 15 018, Part 1 Crane class A1 as per ISO 4301, Part 2...
Page 48: Dimensions And Weights Of The Truck Crane, Axle Loads
1 Overview 1.6 Technical data 1.6.2 Dimensions and weights of the truck crane, axle loads All dimensions in the illustration are in mm. 1 - 8 3 303 279 en Operating manual GMK5150XL...
Page 49 1 Overview 1.6 Technical data à Dimensions All dimensions apply to on-road mode; Driving modes, p. 6 - 1. Length without auxiliary hoist: 14.75 m (48.4 ft) At on-road level height, depending on tyres: – 385/95 R25 3.95 m (12.9 ft) –...
Page 50 1 Overview 1.6 Technical data Weight and axle For equipment with the specified axle loads in on-road mode; à loads Driving modes, p. 6 - 1. Dimensions and weights of the parts that need to be transported on separate à vehicles when driving on the road;...
Page 51: Dimensions And Weights Of Removable Parts
1 Overview 1.6 Technical data 1.6.3 Dimensions and weights of removable parts This section contains the dimensions and weights of the parts that can be à removed for on-road driving; Driving modes, p. 6 - 1. Spare wheel Weight in kg Length x width x height (lbs) Designation...
Page 52 1 Overview 1.6 Technical data Main boom Length x width x Designation Weight in kg (lbs) height in m (ft) Complete main boom 13.55 x 2.15 x 2.10 16,410 (44.45 x 7.05 x 6.90) (36,178) Hook blocks and hook tackle Length x width x height Weight (L) x (W) x (H)
Page 53 1 Overview 1.6 Technical data Counterweight The stability of the crane rigged with the counterweight sections delivered has sections been tested. Counterweight – version 1 Length x width x Weight Pos. Designation 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 54 1 Overview 1.6 Technical data Counterweight – version 2 Length x width x Weight Pos. Designation 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 55 1 Overview 1.6 Technical data Counterweight – version 3 Length x width x Weight Pos. Designation 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 56 1 Overview 1.6 Technical data Counterweight – version 4 Length x width x Weight Pos. Designation 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 57: Carrier
1 Overview 1.6 Technical data 1.6.4 Carrier Engine Mercedes-Benz: OM 471 LA Engine emissions: EU Tier IIIA (US Tier 3) (depending on the version) EU Tier IV (US Tier 4f) EU Tier V (US Tier 4f) Power 390 kW (530 hp) at 1,600 rpm (UN regulation No.
Page 58 1 Overview 1.6 Technical data Axle lines Drive: 10 x 6 x 10 1st axle line: Steered axle line 2nd axle line: Steered and driven axle line 3rd axle line: Steered axle line 4th axle line: Steered and driven axle line, steering can be switched on 5th axle line: Steered and driven axle line Drive:...
Page 59 1 Overview 1.6 Technical data Outriggers Design: 4-point telescoping outrigger system Control system: Can be controlled from both sides on the carrier and individually from the crane cab Outrigger span (standard): Metre (ft) 8.030 m x 7.600 m (26.3 ft x 25.0 ft) 8.030 m x 6.700 m (26.3 ft x 22.0 ft) 8.030 m x 5.900 m (26.3 ft x 19.4 ft) 8.030 m x 5.100 m (26.3 ft x 16.8 ft)
Page 60: Electrical System
1 Overview 1.6 Technical data Electrical system Alternator: 28 V/150 A Batteries: 2 each of 12 V/180 Ah Voltage: 24 V Tools 1 tool kit in tool box, chocks (number according to national regulations) Towing couplings Front towing coupling: 100 kN (22,480 lbf) permissible pull Rear tow lug: 75 kN (16,860 lbf) permissible pull à...
Page 61: Superstructure
1 Overview 1.6 Technical data 1.6.5 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 (in accordance with ISO 4301 - 2) Load spectrum: Load spectrum factor: Km = 0.125...
Page 62 1 Overview 1.6 Technical data Main boom Main boom lengths: 13.0 m to 68.7 m (42.7 ft to 225.4 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 (in accordance with ISO 4301 - 2) Additional equipment à...
Page 63: Documentation Supplied
– Documents from other manufacturers Original documentation for parts not manufactured by Manitowoc Crane Group , such as the engine and central lubrication system, as well as Germany GmbH the tachograph, auxiliary heaters, radio and, where appropriate, other addi- tional equipment.
Page 64: Questions On Documentation
You can find your responsible dealer here: Dealer list, p. 1 - 3. 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 65: Notes On The Operating Manual
1 Overview 1.8 Notes on the operating manual Notes on the operating manual This operating manual is not a training manual for prospective crane operators! All descriptions are written explicitly for crane operators who have been trained to operate truck cranes! This operating manual is designed as a reference manual.
Page 66 1 Overview 1.8 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 within the working range. This symbol draws your attention to situations where there is a risk of receiving an electric shock.
Page 67: How Is The Operating Manual Structured
1 Overview 1.8 Notes on the operating manual 1.8.2 How is the operating manual structured? Division – Chapters 1 to 8 contain a description of how to drive the truck crane. – Chapters 9 to 15 contain a description of crane operation. The complete operating manual must always be stored in the truck crane.
Page 68 1 Overview 1.8 Notes on the operating manual Structure of the Each page in the operating manual is divided into a wide text column and a pages narrow column. The narrow column contains various pieces of information: – Chapter and section numbers, –...
Page 69: How Do I Find The Information I Need
1 Overview 1.8 Notes on the operating manual 1.8.3 How do I find the information I need? The operating manual contains the following guides for orientation. – The Contents list all chapters in the operating manual. – The Table of contents provides an overview of the topics. –...
Page 70 1 Overview 1.8 Notes on the operating manual Cross-reference 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 3 303 279 en Operating manual GMK5150XL...
Page 71 1 Overview 1.8 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 2.
Page 72: What Information Is Available For Operations Planning
1 Overview 1.8 Notes on the operating manual 1.8.4 What information is available for operations planning? Extensive information is required for operations planning in order to ensure safe, smooth and efficient operation of the truck crane: The operating manual contains à...
Page 73: Conversion Table For Us Units Of Measurement
1 Overview 1.9 Conversion table for US units of measurement Conversion table for US units of measurement The following conversion factors will help you convert from metric to US units when the truck crane is used in countries that use US units of measurement and vice versa.
Page 74 1 Overview 1.9 Conversion table for US units of measurement Blank page 1 - 34 3 303 279 en Operating manual GMK5150XL...
Page 75: Training - Information
1.10 Training – Information 1.10 Training – Information For the EMEA region (Europe, Middle East, Africa) Manitowoc Crane Group offers comprehensive training for all GMK models. Germany GmbH Our training centre is located in a maritime environment, on Germany's North Sea coast at Wilhelmshaven.
Page 76: Identification
1 Overview 1.11 Identification 1.11 Identification 1 - 36 3 303 279 en Operating manual GMK5150XL...
Page 77 1 Overview 1.11 Identification The following plates and numbers are attached to the truck crane for identification purposes: 1 Serial number and crane type 2 the CE marking, which is only applicable to truck cranes whose equipment and configuration comply with the guidelines and standards specified in the supplied EC Declaration of Conformity.
Page 78: Ec Declaration Of Conformity
1 Overview 1.12 EC Declaration of Conformity 1.12 EC Declaration of Conformity On initial delivery, operators of truck cranes receive a Declaration of Conformity as a supple- ment to the delivery report. An illustration of a sample Declaration of Conformity is shown below.
Page 79 2 Basic safety instructions 2.1 Observe the safety manual Basic safety instructions For a list and explanation of all symbols used in this operating manual for safety à instructions and other notes; What do the symbols used mean?, p. 1 - 25. Observe the safety manual Risk of accidents if the safety manual is not observed.
Page 80: Intended Use
The truck crane may only be modified with the approval of Manitowoc Crane Group Germany GmbH The GMK5150XL truck crane may be used only when it is in perfect technical condition and for its intended purpose and with due attention paid to safe opera- tion and possible hazards.
Page 81: Improper Use
2.3 Improper use Improper use is not liable for damage resulting from Manitowoc Crane Group Germany GmbH improper or unauthorised use of the GMK5150XL. The user alone bears the risk. Improper use includes – Transporting loads on the carrier – an exception are equipment parts (e.g.
Page 82 2 Basic safety instructions 2.3 Improper use Blank page 2 - 4 3 303 279 en Operating manual GMK5150XL...
Page 83: Operating Elements For Driving
3 Operating elements for driving 3.1 Overview – Notes Operating elements for driving All operating elements for crane operation are described in Chapter 9. This operating manual contains illustrations of the GMK5150L-1 with five telescopic sections. The GMK5150XL has six telescopic sections (1). The illustrations have only been modified where relevant for operation.
Page 84: Overview - Exterior Of The Truck Crane
3 Operating elements for driving 3.2 Overview – Exterior of the truck crane Overview – Exterior of the truck crane 3 - 2 3 303 279 en Operating manual GMK5150XL...
Page 85 3 Operating elements for driving 3.2 Overview – Exterior of the truck crane à 1 Front flap p. 3 - 84 à 2 Driver's cab overview p. 3 - 8 1), 2) 3 Hose drum, installation/removal à 4 Engine p. 4 - 1 à...
Page 86 3 Operating elements for driving 3.2 Overview – Exterior of the truck crane 3 - 4 3 303 279 en Operating manual GMK5150XL...
Page 87 3 Operating elements for driving 3.2 Overview – Exterior of the truck crane à 17 Raising/lowering the 3rd axle line p. 6 - 15 à 18 AdBlue (DEF) tank p. 4 - 8 à 19 Battery master switch II p. 3 - 55 à...
Page 88 3 Operating elements for driving 3.2 Overview – Exterior of the truck crane Blank page 3 - 6 3 303 279 en Operating manual GMK5150XL...
Page 89: Outrigger Control Units
3 Operating elements for driving 3.2 Overview – Exterior of the truck crane 3.2.1 Outrigger control units Contains operating elements for crane operation; à Outrigger control units, p. 9 - 7. Operating manual 3 303 279 en 3 - 7 GMK5150XL...
Page 90: Driver's Cab Overview
3 Operating elements for driving 3.3 Driver's cab overview Driver's cab overview 3.3.1 Front overview 3 - 8 3 303 279 en Operating manual GMK5150XL...
Page 91 3 Operating elements for driving 3.3 Driver's cab overview à 1 Handle p. 3 - 87 à 2 Top operating elements p. 3 - 12 3 Sun visors à 4 Cab lighting p. 3 - 77 à 5 Air vents p.
Page 92: Rear Overview
3 Operating elements for driving 3.3 Driver's cab overview 3.3.2 Rear overview 3 - 10 3 303 279 en Operating manual GMK5150XL...
Page 93 3 Operating elements for driving 3.3 Driver's cab overview à 1 Adjusting the passenger seat p. 5 - 15 2 Coat hook à 3 – Storage compartment p. 5 - 8 à – Auxiliary air heater – driver’s cab p. 5 - 101 à...
Page 94: Top Operating Elements
3 Operating elements for driving 3.3 Driver's cab overview 3.3.3 Top operating elements à 1 Auxiliary air heater – battery p. 3 - 27 à 2 Auxiliary air heater – driver’s cab p. 3 - 27 à 3 Auxiliary water heating system p.
Page 95 3 Operating elements for driving 3.3 Driver's cab overview Tachograph à p. 5 - 20 (A) – Tachograph à 1 Display p. 5 - 23 à 2 Time correction – p. 3 - 80 à 3 Time correction + p. 3 - 80 à...
Page 96: Left Operating Elements
3 Operating elements for driving 3.3 Driver's cab overview 3.3.4 Left operating elements à 1 Air vent p. 5 - 90 à 2 Battery master switch I p. 3 - 55 à 3 Central locking system p. 3 - 86 à...
Page 97: Right Operating Elements
3 Operating elements for driving 3.3 Driver's cab overview 3.3.5 Right operating elements à 1 Air vent p. 5 - 90 2 Free for special equipment à Separate operating manual Operating manual 3 303 279 en 3 - 15 GMK5150XL...
Page 98: Centre Control Unit
3 Operating elements for driving 3.3 Driver's cab overview 3.3.6 Centre control unit 3 - 16 3 303 279 en Operating manual GMK5150XL...
Page 99 3 Operating elements for driving 3.3 Driver's cab overview à 1 Turn signal indicator lamp p. 3 - 74 à 2 Trailer turn signal indicator lamp p. 3 - 74 à 3 Speedometer p. 3 - 80 à 4 On-board computer operating elements p.
Page 100 3 Operating elements for driving 3.3 Driver's cab overview Blank page 3 - 18 3 303 279 en Operating manual GMK5150XL...
Page 101: Side Operating Elements
3 Operating elements for driving 3.3 Driver's cab overview 3.3.7 Side operating elements à 1 CCS control unit p. 3 - 30 à 2 BirdView system 270° – monitor p. 3 - 64 à 3 Rotating beacons on/off p. 3 - 75 à...
Page 102: Steering Column/Steering Wheel Operating Elements
3 Operating elements for driving 3.3 Driver's cab overview 3.3.8 Steering column/steering wheel operating elements à 1 On-board computer operating elements p. 3 - 22 2 Operation: à – Setting idling speed p. 3 - 51 à – Setting the cruise control p.
Page 103 3 Operating elements for driving 3.3 Driver's cab overview Transmission operating elements à 1 Select transmission mode p. 3 - 61 à 2 Change operating mode p. 3 - 61 à 3 Perform change of gear p. 3 - 62 à...
Page 104: On-Board Computer Operating Elements
3 Operating elements for driving 3.3 Driver's cab overview 3.3.9 On-board computer operating elements à 1 On-board computer display p. 3 - 23 à 2 Selector buttons p. 3 - 82 à 3 Opening/closing windows for input p. 3 - 83 à...
Page 105 3 Operating elements for driving 3.3 Driver's cab overview On-board computer display 1 Menu groups à – Overview p. 3 - 24 à – Selecting a menu group p. 3 - 82 à 2 Display open menu (name) p. 3 - 82 à...
Page 106 3 Operating elements for driving 3.3 Driver's cab overview Overview of menu groups 1 Tour data menu group à Truck info menu p. 5 - 27 à From start menu p. 5 - 28 à Range menu p. 5 - 28 à...
Page 107 3 Operating elements for driving 3.3 Driver's cab overview 4 Maintenance menu group à Maintenance menu p. 5 - 30 5 Monitoring and information menu group à Supply pressure menu p. 5 - 32 à Coolant menu p. 5 - 32 à...
Page 108: Heating And Air-Conditioning System Operating Elements
3 Operating elements for driving 3.3 Driver's cab overview 3.3.10 Heating and air-conditioning system operating elements Standard à 1 Setting the fan p. 5 - 89 à 1), 2) 2 Preheating display on/off p. 5 - 98 à 3 Air-conditioning system p.
Page 109: Auxiliary Heater
3 Operating elements for driving 3.3 Driver's cab overview Auxiliary heater à A Auxiliary air heater – battery p. 5 - 103 à B Auxiliary air heater – driver’s cab p. 5 - 101 à C Auxiliary water heating system p.
Page 110: Door Operating Elements
3 Operating elements for driving 3.3 Driver's cab overview 3.3.11 Door operating elements 3 - 28 3 303 279 en Operating manual GMK5150XL...
Page 111 3 Operating elements for driving 3.3 Driver's cab overview A Driver's door à 1 Mirror heating p. 5 - 9 à 2 Adjusting mirrors p. 5 - 9 à 3 Window winder Driver’s door p. 3 - 85 à 4 Window winder Passenger door p.
Page 112: Crane Control Operating Elements
3 Operating elements for driving 3.4 Crane control operating elements Crane control operating elements 3.4.1 CCS control unit 3 - 30 3 303 279 en Operating manual GMK5150XL...
Page 113 3 Operating elements for driving 3.4 Crane control operating elements 1 CCS display à Overview start menu p. 3 - 33 à 2 Service/diagnostics connection p. 3 - 81 à 3 Exit menu/input mode p. 3 - 58 à 4 Selector buttons p.
Page 114: Ccs - Menu-Dependent Displays
3 Operating elements for driving 3.4 Crane control operating elements 3.4.2 CCS – Menu-dependent displays à 1 Transverse differential locks display p. 3 - 67 à Longitudinal differential lock display p. 3 - 67 à 2 Suspension display p. 3 - 72 à...
Page 115: Ccs - Start Menu
3 Operating elements for driving 3.4 Crane control operating elements 3.4.3 CCS – Start menu 1 Crane type display 2 Serial number display à 3 Display of transverse and longitudinal differential p. 3 - 38 locks on/off à 4 Voltage monitoring display p.
Page 116: Ccs - Overview Of Menu Groups
3 Operating elements for driving 3.4 Crane control operating elements 3.4.4 CCS – Overview of menu groups 3 - 34 3 303 279 en Operating manual GMK5150XL...
Page 117 3 Operating elements for driving 3.4 Crane control operating elements à 1 Carrier menu group p. 3 - 36 – Suspension/level adjustment menu – Driving menu – Exhaust system menu – Air intake inhibitor menu à 2 Settings menu group p.
Page 118: Carrier Menu Group
3 Operating elements for driving 3.4 Crane control operating elements 3.4.5 Carrier menu group à 1 Suspension/level adjustment menu p. 3 - 37 à 2 Driving menu p. 3 - 38 à 3 Exhaust system menu p. 3 - 39 à...
Page 119 3 Operating elements for driving 3.4 Crane control operating elements Suspension/level adjustment menu à 1 Switching the horn on/off p. 3 - 79 à 2 Front level pre-selection p. 3 - 77 à 3 Level adjustment system enabled display p. 3 - 78 à...
Page 120 3 Operating elements for driving 3.4 Crane control operating elements Driving menu à 1 Current wheel position display p. 3 - 72 à 2 – Transverse differential locks display p. 3 - 67 à – Transverse differential locks on/off p. 3 - 67 à...
Page 121 3 Operating elements for driving 3.4 Crane control operating elements Exhaust system menu A Only for EU Tier IV à 1 Override torque reduction p. 3 - 53 B Only for EU Tier V à 1 Override torque reduction p. 3 - 53 à...
Page 122 3 Operating elements for driving 3.4 Crane control operating elements Air intake inhibitor menu 1), 2) 1 Close air intake inhibitor à 2 Opening the air intake inhibitor p. 3 - 55 1), 2) 3 Air intake inhibitor maintenance Additional equipment à...
Page 123: Settings Menu Group
3 Operating elements for driving 3.4 Crane control operating elements 3.4.6 Settings menu group à 1 Set display brightness menu p. 3 - 42 à 2 Switch over outrigger span display p. 9 - 113 Operating manual 3 303 279 en 3 - 41 GMK5150XL...
Page 124 3 Operating elements for driving 3.4 Crane control operating elements Set display brightness menu 1 Set display brightness selection 2 Increase/reduce value à p. 5 - 17 3 Display in percent 4 Display brightness display 3 - 42 3 303 279 en Operating manual GMK5150XL...
Page 125: Information Menu Group
3 Operating elements for driving 3.4 Crane control operating elements 3.4.7 Information menu group à 1 Operating hours menu p. 3 - 44 à 2 Engine/transmission error menu p. 3 - 45 à 3 Crane operation error menu p. 3 - 46 Operating manual 3 303 279 en 3 - 43...
Page 126 3 Operating elements for driving 3.4 Crane control operating elements Operating hours menu 1 Key code input 2 Carrier à 3 Engine p. 5 - 25 4 Transmission 5 Select all 3 - 44 3 303 279 en Operating manual GMK5150XL...
Page 127 3 Operating elements for driving 3.4 Crane control operating elements Engine/ transmission error menu 1 Displaying errors / total errors 2 Engine symbol display 3 Transmission symbol display à p. 8 - 37 4 Error code display 5 Previous error 6 Next error Operating manual 3 303 279 en...
Page 128 3 Operating elements for driving 3.4 Crane control operating elements Crane operation error menu 1 Current errors / total errors display 2 Error code à 3 Delete error p. 14 - 5 4 Next error 5 Previous error 3 - 46 3 303 279 en Operating manual GMK5150XL...
Page 129: Various Controls Menu Group
3 Operating elements for driving 3.4 Crane control operating elements 3.4.8 Various controls menu group à 1 Outrigger lighting on/off p. 3 - 76 à 2 Reversing camera on/off p. 3 - 63 Operating manual 3 303 279 en 3 - 47 GMK5150XL...
Page 130: Emergency Operations Menu Group
3 Operating elements for driving 3.4 Crane control operating elements 3.4.9 Emergency operations menu group à 1 Switching emergency operation on/off p. 14 - 67 à 2 Switching towing mode on/off p. 8 - 48 (Transfer case neutral position on/off) à...
Page 131: Brief Description Of The Operating Elements
3 Operating elements for driving 3.5 Brief description of the operating elements Brief description of the operating elements Risk of accident by operating error! This section is not a complete operating manual. It only provides a general overview of the functionality of the operating elements. Before using the operating elements for the first time, read through the following chapters and the safety instructions listed there.
Page 132: General Rules For Buttons And Symbols On The Display
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.2 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 133: Engine
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.3 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 134 3 Operating elements for driving 3.5 Brief description of the operating elements Setting the cruise control The truck crane is driving at a speed of at least 15 km/h (9 mph). 3 Select Cruise control – symbol (1) grey 4 Switches on or increases the speed –...
Page 135: Adblue (Def) System
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.4 AdBlue (DEF) system CCS display Exhaust system menu – Open: Select and confirm symbol (1) Override torque reduction Torque reduction is active 1 – Select and confirm: –...
Page 136 3 Operating elements for driving 3.5 Brief description of the operating elements Exhaust system cleaning required Lights up or flashes in yellow or red, depending on the current status. Is always displayed together with other lamps or messages on the on-board à...
Page 137: Air Intake Inhibitor
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.6 Air intake inhibitor Air intake inhibitor menu – Open: Select and confirm symbol (1) Opening the air intake inhibitor The air intake inhibitor was automatically triggered. 1 – Select and confirm: Symbol (1) green –...
Page 138 3 Operating elements for driving 3.5 Brief description of the operating elements Blank page 3 - 56 3 303 279 en Operating manual GMK5150XL...
Page 139: Electrical System
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.8 Electrical system 12 V/24 V sockets 1 12 V/max. 15 A – can be switched on/off 2 24 V/max. 15 A 3 Cigarette lighter 24 V/max. 15 A Only connect electrical devices with the matching specification to the sockets.
Page 140: Ccs Crane Control
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.9 CCS crane control The GMK5150XL 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 super- structure and carrier.
Page 141 3 Operating elements for driving 3.5 Brief description of the operating elements Exit menu/input mode 1 Press: – The open menu closes – the menu from the next higher level is opened – Input mode is disabled. Overview of menu groups 1 Press: –...
Page 142 3 Operating elements for driving 3.5 Brief description of the operating elements Select / deselect favourites Several favourites can be selected. The cursor jumps directly from favourite to favourite when scrolling through the menu groups. Select A symbol is selected, such as symbol (1). 2 Press The symbol is marked as a favourite.
Page 143: Transmission
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.10 Transmission à Operating the transmission, p. 5 - 41. Description of further displays for warning and fault messages; à Warning and fault messages on the on-board computer, p. 8 - 7. Transmission Select transmission mode control unit...
Page 144 3 Operating elements for driving 3.5 Brief description of the operating elements Perform change of gear The truck crane is stationary – Push up once: Shift up starting gear – 1 gear – Push down once: Shift down starting gear – 1 gear The truck crane is driving In Manual operating mode –...
Page 145: Reversing Camera
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.11 Reversing camera The reversing camera (1) displays the area behind the truck crane on the CCS display in the driver's cab. The reversing lamps (2) are automatically switched on and off, together with the standard à...
Page 146: Birdview System 270
Drive with due care and atten- tion! The sole responsibility lies with you as 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 147: Switching Off
3 Operating elements for driving 3.5 Brief description of the operating elements The cameras must not be removed or misaligned. If a camera is mounted on the storage box then the storage box must not be removed. There must be no spare wheel installed on the rear of carrier. Switching on •...
Page 148: Transfer Case
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.13 Transfer case à Transfer case – switching the off-road gear on/off, p. 5 - 70 Driving menu – Open: Select and confirm symbol (1) Transfer case off-road gear on/off –...
Page 149: Final Drive
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.14 Final drive à Longitudinal and transverse differential locks, p. 5 - 71 Driving menu – Open: Select and confirm symbol (1) Transverse differential locks on/off – Switch on: Select symbol (1) and confirm –...
Page 150: Brakes
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.15 Brakes Service brake Description of further symbols for warning and fault messages; à Warning messages on the centre control unit, p. 8 - 3. The braking force can be continuously adjusted with the pedal. On-board computer In the Supply pressure submenu, 1 Current supply pressure in brake circuit 1...
Page 151: Parking Brake
3 Operating elements for driving 3.5 Brief description of the operating elements Centre control unit Additional brake indicator lamp – Lights up: Additional brake on – Gone out: Additional brake off – Flashing: – Ignition on – multipurpose switch not in setting 0 –...
Page 152: Steering
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.16 Steering Description of the symbols for warning and fault messages; à Warning messages on the centre control unit, p. 8 - 3. 3.5.17 Separate steering à Separate steering, p. 5 - 79 Driver's door Separate manual steering The separate manual steering must be switched on.
Page 153 3 Operating elements for driving 3.5 Brief description of the operating elements The following applies to all steering modes: The selected symbol must be confirmed within 2 seconds, otherwise the steering mode remains unchanged. Normal steering mode, on-road driving on/off –...
Page 154: Suspension
3 Operating elements for driving 3.5 Brief description of the operating elements Current wheel position display The current status is shown using different symbols: 1 Straight ahead 2 Driving around corners 3 Crab travel mode 4 End position reached – e.g. when driving around corners 3.5.18 Suspension...
Page 155: Lighting/Windscreen Wipers/Horn
3 Operating elements for driving 3.5 Brief description of the operating elements Suspension operation pressure display 1 Suspension pressure for 1st and 2nd axle lines on the left 2 Suspension pressure for 1st and 2nd axle lines on the right 3 Suspension pressure for 3rd to 5th axle lines on the left 4 Suspension pressure for 3rd to 5th axle lines on the right 3.5.19...
Page 156 3 Operating elements for driving 3.5 Brief description of the operating elements Turn signal indicator/wiper-washing system 4 Right turn signal indicator: Forwards 5 Left turn signal indicator: Backwards 6 Windscreen wiper/washing system: Press 7 Windscreen wiper: Rotate: – Off, – Interval – slow –...
Page 157 3 Operating elements for driving 3.5 Brief description of the operating elements Lights display – Lights up: Parking light, low-beam headlight, ambient light or headlight flasher on – Gone out: Lights off Left operating elements Spotlights III on/off – Switch on: Press at bottom –...
Page 158: Lights On/Off
3 Operating elements for driving 3.5 Brief description of the operating elements Lights on/off – Parking light/headlight 1 Light off 2 Parking light on Instrument lighting on 3 Headlight on Full beam headlight can be switched on using the multipurpose switch –...
Page 159: Level Adjustment System
3 Operating elements for driving 3.5 Brief description of the operating elements Roof The lamps on the driver's side and the passenger side are identical. Cab lighting 1 Switch on continuously 2 Switch off continuously 3 On/off via door contact Reading lamp 1 Switching on 2 Switching off...
Page 160 3 Operating elements for driving 3.5 Brief description of the operating elements Level adjustment system enabled display 1 – Displayed Level pre-selection on, buttons (2) and (3) active. – Hidden Level pre-selection off, buttons (2) and (3) not active. Level change The movement stops after the button is released and when an end position is reached.
Page 161 3 Operating elements for driving 3.5 Brief description of the operating elements Current inclination display 1 Directional indicator 2 Inclination indicator 3 Measuring range display à p. 5 - 76 Switching over the measuring range The current measuring range 1° or 5° is displayed – automatic change-over à...
Page 162: Tachograph/Speedometer
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.21 Tachograph/speedometer à Setting the tachograph, p. 5 - 20. Tachograph The time correction is carried out 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 163: Diagnostics
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.22 Diagnostics The diagnostic connections may only be operated by service staff from the engine manufacturer/transmission manufacturer, or by Grove Product Support The diagnostic connections (2) are in the storage compartment, behind the cover (1).
Page 164: On-Board Computer
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.23 On-board computer à Settings and displays at the on-board computer, p. 5 - 26. On-board computer display After switching on the ignition, the display (1) briefly shows the Start Check menu and the electronics system records the current state.
Page 165 3 Operating elements for driving 3.5 Brief description of the operating elements Opening windows for making entries The symbol (6) is displayed. Press button (5) the window (7) opens. – Entering values / opening further windows Make the desired selection depending on the menu.
Page 166: Front Flap
3 Operating elements for driving 3.5 Brief description of the operating elements Mobile phone operating elements The buttons are only active if there are a suitable mobile phone and radio. These devices are not included in the scope of delivery. For connecting à...
Page 167: Windows And Doors
3 Operating elements for driving 3.5 Brief description of the operating elements 3.5.25 Windows and doors Window winder There may also be window cranks, depending on the equipment. Risk of crushing when closing the windows! If the window winders encounter resistance, they do not stop but keep on moving at reduced power.
Page 168 3 Operating elements for driving 3.5 Brief description of the operating elements Doors Operation with key and handle The same key is used for the driver's and passenger doors. Always take the ignition key with you before closing the door from outside with the handle pressed in (3).
Page 169: Access Aids And Ladders
3 Operating elements for driving 3.5 Brief description of the operating elements With remote control The buttons must be pressed for about 1 second for the operation to be carried out. Unlocking • Press the button (1) – the lamp (3) flashes – the driver’s door is unlocked.
Page 170 3 Operating elements for driving 3.5 Brief description of the operating elements . Crane cab – When the crane cab door is open, you can reach the handle (1). – The handle (2) is on the outside of the crane cab.
Page 171 3 Operating elements for driving 3.5 Brief description of the operating elements – Folding in • Release the spring latch (5) and push in the step (4). • Lift the locking bar (3) for releasing and fold the ladder (2) up. •...
Page 172 3 Operating elements for driving 3.5 Brief description of the operating elements Folding ladder – storage under the driver's à For storage on the rear of carrier; p. 3 - 89. – For use Ladder (1) – for erecting and fold out. •...
Page 173: Starting The Engine / Switching It Off - For Driving
4 Starting the engine / switching it off – for driving Starting the engine / switching it off – for driving This chapter describes how to start the engine / switch it off from within the driver's cab and at the outrigger control units. For starting the engine / switching it off from within the crane cab or using the à...
Page 174 4 Starting the engine / switching it off – for driving Blank page 4 - 2 3 303 279 en Operating manual GMK5150XL...
Page 175: Starting The Engine From The Driver's Cab
4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab Starting the engine from the driver's cab For Euromot 5 VO engine emissions: Please note that crane operation is not possible while the exhaust system is being cleaned. Always check the status of the exhaust system and always initiate required exhaust cleaning before starting à...
Page 176 4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab à 4. – Switch on battery master switch II (2) – if present; p. 5 - 87. à – Switch on battery master switch I (1); p.
Page 177 4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab 9. Check the consumables supply à Fuel tank, p. 4 - 7 à AdBlue (DEF) tank, p. 4 - 8 à Crane cab heater fuel tank, p.
Page 178: Checklist: At Low Temperatures
4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab 4.1.2 CHECKLIST: At low temperatures You must also observe the following when operating the truck crane at low outside temperatures: 1. The fuel and engine oil must be suitable for use at the respective outside à...
Page 179: Refuelling
4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab 4.1.3 Refuelling à Fuel tank Only use permissible consumables; Separate engine manufacturer's operating manual. Danger of fire due to flammable gases! Switch off the engine, the heating system and all auxiliary heaters before refuelling.
Page 180 4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab AdBlue (DEF) tank AdBlue (DEF) is a consumable for exhaust treatment. For AdBlue (DEF), there are registered trademarks of the Kruse GmbH & Co KG and BASF SE companies and the German Association of the Automotive Industry.
Page 181 4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab The displays (1) and (2) indicate the AdBlue (DEF) supply. The tank is refilled via the filler neck (3). • Top up AdBlue (DEF) in due time, and close the tank with the cap.
Page 182: Checks Before Starting The Engine
4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab 4.1.4 Checks before starting the engine On the hydraulic Before you start the engine, all valves on the hydraulic tank must be open. tank Risk of damage to the hydraulic pumps! You may only start the engine when all the valves on the hydraulic tank are open!
Page 183: Switching On The Ignition
4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab Checking the Check that the hand-held control has been removed, and that the bridging plugs à hand-held control for the hand-held control are inserted into all sockets; p.
Page 184: Lamp Test/Synchronisation Of The Switching States
4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab 4.1.6 Lamp test/synchronisation of the switching states Lamp test After the ignition has been switched on, a lamp test is performed. Risk of accidents from faulty lamps! The lamps that are used to provide warnings and information during operation light up for control purposes whenever the ignition is switched on.
Page 185: Starting The Engine
4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab 4.1.7 Starting the engine This section only describes how to start the engine from the driver's cab. You can à also start the engine at the outrigger control units; p.
Page 186 4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab This section is for starting a warm and cold engine. Danger of explosion when using starter fuel! The engine must never be started with the aid of starter fuel. Starter fuel sprayed into the suction unit can ignite.
Page 187: Checks After Starting The Engine
4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab 4.1.8 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 188 4 Starting the engine / switching it off – for driving 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 189: Setting Idling Speed
4 Starting the engine / switching it off – for driving 4.1 Starting the engine from the driver's cab 4.1.9 Setting idling speed After the engine is started, the idling speed is controlled automatically. If necessary, you can adjust the idling speed manually. You can only set the idling speed when the truck crane is stationary.
Page 190: Starting The Engine - At The Outrigger Control Units
4 Starting the engine / switching it off – for driving 4.2 Starting the engine – at the outrigger control units Starting the engine – at the outrigger control units You can generally only start the engine if a bridging plug is inserted in all sockets à...
Page 191: Switching Off The Engine
4 Starting the engine / switching it off – for driving 4.3 Switching off the engine Switching off the engine 4.3.1 In the driver’s cab 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 192: With Emergency Stop Switches
4 Starting the engine / switching it off – for driving 4.3 Switching off the engine 4.3.3 With emergency stop switches Do not use the emergency stop switch to switch the engine off during normal operation. Only use the emergency stop switch in an emergency situation. Three emergency stop switches are provided for emergency use: 1 On the carrier –...
Page 193 4 Starting the engine / switching it off – for driving 4.4 Air intake inhibitor Air intake inhibitor If the air intake inhibitor is triggered, a flap in the air intake line closes and the engine stops running – symbol (1) is displayed. The air intake inhibitor is triggered, –...
Page 194 4 Starting the engine / switching it off – for driving 4.4 Air intake inhibitor Blank page 4 - 22 3 303 279 en Operating manual GMK5150XL...
Page 195: Driving Mode
5 Driving mode 5.1 Before driving Driving mode 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 given there! 1.
Page 196 5 Driving mode 5.1 Before driving à – Depending on requirements, the 3rd axle line is raised; p. 6 - 15. – The turntable is unlocked – provided the systems are present; à Unlocking the superstructure, p. 11 - 16 à...
Page 197 5 Driving mode 5.1 Before driving à 8. All railings are folded in; p. 12 - 169. 9. The step on the crane cab is retracted or pushed in, depending on the version. à – Retract; Automatic operation, p. 12 - 178 à...
Page 198 5 Driving mode 5.1 Before driving 14. The warning signs for marking the vehicle width are folded down (only for vehicle widths of over 2.75 m (9.0 ft)); à Vehicle width; p. 1 - 8, à Warning signs; p. 5 - 10. 15.
Page 199 5 Driving mode 5.1 Before driving à 19. Switch on the ignition;. p. 4 - 11 20. The driver’s cab is lowered to the end position – the symbol has gone out, à if there is any monitoring; p. 8 - 64. à...
Page 200 5 Driving mode 5.1 Before driving 25. Adjust the brightness of the instrument panel as necessary; à Lighting menu, p. 5 - 35. à 26. Set the tachograph, insert the diagram sheet; p. 5 - 20. à 27. Start the engine and carry out all checks; Checks after starting the engine, p.
Page 201 5 Driving mode 5.1 Before driving 31. Check that all switching states for on-road driving are set, and that the cor- responding symbols are shown: à – Suspension switched on; p. 5 - 19, à – Longitudinal and transverse differential locks switched off; p.
Page 202: Checking The Condition Of The Truck Crane
5 Driving mode 5.1 Before driving 5.1.2 Checking the condition of the truck crane • Electrical system Check the listed functions and have faulty parts repaired. – Parking light/headlight, full beam headlight, headlight flasher, side marker lights – Brake lights, reversing lights, reversing lamps, buzzer –...
Page 203: Adjusting Mirrors
5 Driving mode 5.1 Before driving Adjusting mirrors Adjust all the mirrors to suit your sitting position. Manual adjustment • Manually adjust the mirrors (1), (3) and (4). The mirrors (2) are adjusted electrically on both sides. Electrical adjustment • Turn the button to position A Neutral position B Mirror on the driver's side or...
Page 204 5 Driving mode 5.1 Before driving Warning plates for Depending on the vehicle width and equipment, folding warning plates are fitted vehicle width below the driver's cab. The warning plates (1) must be folded down to indicate the vehicle width during on-road driving. For off-road driving, the warning plates can be folded up and fastened with the locking bar (2).
Page 205 5 Driving mode 5.1 Before driving Supply pressure The brake system and some electrical devices (e.g. differential locks, driver's seat, trailer etc.) require sufficient supply pressure in order work properly. • Open the menu (1) – Supply pressure menu. • Check that the supply pressure is approx.
Page 206 5 Driving mode 5.1 Before driving Parking brake Check the function of the parking brake. • Operate the service brake. Risk of accidents due to the truck crane moving unintentionally! Always apply the service brake before releasing the parking brake. This prevents the truck crane rolling in an uncontrolled manner when the parking brake is released.
Page 207 5 Driving mode 5.1 Before driving Additional If there is an additional rear light, then you must check to ensure it is correctly information connected. Rear light There is an additional rear light (1) at the rear of carrier. If there is a storage box is present, then there is another additional rear light (2) there.
Page 208: Adjusting The Seat And The Steering Column
5 Driving mode 5.1 Before driving 5.1.3 Adjusting the seat and the steering column Adjusting the The seat height and lumbar area 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 209 5 Driving mode 5.1 Before driving Settings for body shape 1 Lower lumbar area support 2 Upper lumbar area support 3 Seat heating on/off Additional equipment The settings are made pneumatically. The following applies to all buttons: Deflate the air cushion: Press –...
Page 210 5 Driving mode 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 has à...
Page 211: Display - Adjusting The Brightness
5 Driving mode 5.1 Before driving 5.1.4 Display – Adjusting the brightness The brightness of the display can also be adjusted manually. In the driver's cab You can set two brightness values. – A value when the headlight is switched off. –...
Page 212: Switching The Suspension On/Off
5 Driving mode 5.1 Before driving 5.1.5 Switching the suspension on/off The suspension is switched off whenever the ignition is switched off. The suspension must be switched on for on-road driving. The current switching state of the suspension is shown on the display (1) in all menus. Symbol green: Suspension is switched on Symbol red:...
Page 213 5 Driving mode 5.1 Before driving Switching on the The suspension cylinders are enabled when the suspension is switched on. suspension 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
5 Driving mode 5.1 Before driving 5.1.6 Setting the tachograph The diagram sheets (24-hour discs) can be inserted into the tachograph for two drivers simultaneously. As a crane operator, you are obliged to set each activity at the tachograph. This section only describes the basic operation of the tachograph (inserting diagram sheets, setting time groups, operating errors).
Page 215 5 Driving mode 5.1 Before driving Setting the To set the tachograph, you must first open the drawer and check the time setting. tachograph You can then insert the diagram sheets and set the time groups. Opening the drawer • Press the button (6) once.
Page 216 5 Driving mode 5.1 Before driving Inserting diagram sheets Only insert diagram sheets that are correctly labelled. 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 labelled several times, this might cause malfunctions in the electronics.
Page 217 5 Driving mode 5.1 Before driving Display If no malfunction 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: Setting The Time
5 Driving mode 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 two diagram sheets are inserted, the tachograph automatically switches to stand-by time for 2-driver operation.
Page 219: Displaying And Resetting Operating Hours
5 Driving mode 5.1 Before driving 5.1.8 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 220: Settings And Displays At The On-Board Computer
5 Driving mode 5.1 Before driving 5.1.9 Settings and displays at the on-board computer This section only describes those menus that display various values and in which settings can be made. à If the display shows a warning message (1); Warning and fault messages on the on-board computer, p.
Page 221 5 Driving mode 5.1 Before driving Selecting a menu The name (6) of the selected menu is displayed. The marking (7) shows the level of the menu, e.g. the menu (8) at level 1. • Press the button (1) or (3) to select the desired menu –...
Page 222 5 Driving mode 5.1 Before driving From start menu Recording the displayed values starts with the last driving start. After a four hour standstill period, the values are automatically reset. 1 Driven distance 2 Driven time 3 Average speed 4 Average consumption –...
Page 223 5 Driving mode 5.1 Before driving Reset 1 menu Reset 2 menu Recording the displayed values started during the last reset in the corresponding menu. 5 Marking for Reset 1 menu 6 Marking for Reset 2 menu Meaning of the values (1) to (4), display of further values and resetting the values;...
Page 224 5 Driving mode 5.1 Before driving – Setting the alarm • Open the window – button (5). 6 Selection of alarm 1 / alarm 2 7 Selection of alarm off / buzzer / audio 8 Input of alarm time in hours 9 Input of alarm time in minutes Suitable audio device required •...
Page 225 5 Driving mode 5.1 Before driving – Displaying deadlines • Open the window – button (5). 6 Component – (time maintenance, engine, transmission, air filter, X axle brake) 7 Maintenance deadline 8 Remaining distance If no deadline (7) can be determined yet, (9) is displayed.
Page 226 5 Driving mode 5.1 Before driving – Resetting deadlines A deadline may only be reset if the corresponding maintenance task was carried out. If a deadline is accidentally reset, consult Grove Product Support Risk of damage if the maintenance deadlines are reset! After the reset, the system calculates a new maintenance deadline.
Page 227 5 Driving mode 5.1 Before driving Engine menu For a meaningful oil level display, various prerequisites must be fulfilled. – The truck crane is horizontal. – The parking brake is applied. – After shutting down the engine at least 5 minutes have passed. –...
Page 228 5 Driving mode 5.1 Before driving Events menu 1 Number of stored messages, e.g. 2 The messages can be displayed until the cause is eliminated. – Displaying messages • Display first message – button (5). • Display further messages – button (1) or (3). Diagnostics menu Menu for service personnel •...
Page 229 5 Driving mode 5.1 Before driving – Switching over the time • Open the window – button (5). • Select line – button (1) or (3). 6 Switch over 12 h/24 h display – button (2) or (4) 7 Enter deviation from the UTC time –...
Page 230 5 Driving mode 5.1 Before driving – Instrument panel No adjustment is possible if the headlight is switched off – (6) Day mode is displayed. If the headlight is switched on, a bar chart (7) is displayed for the adjustment. •...
Page 231 5 Driving mode 5.1 Before driving – Setting • Open the window – button (5). The set language (6) is highlighted. • Select language – button (1) or (3). • Set language – button (2). Consumables menu For a meaningful display in the Maintenance menu, it is necessary that the values of the currently used consumables are entered.
Page 232 5 Driving mode 5.1 Before driving – EcoRoll mode (overview) After switching on the ignition, EcoRoll mode is switched on and is activated when driving in Automatic operating mode. In EcoRoll mode, the transmission shifts to neutral position depending on the current driving situation when you release the pedal at a speed of at least approx.
Page 233 5 Driving mode 5.1 Before driving Driving systems This menu group is not selected via a symbol on the on-board computer display. menu group The menus are opened directly with a button. Idling speed menu • Open the window – 1x button (6). •...
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Page 235: Operating The Transmission
5 Driving mode 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.
Page 236: Switching The Transmission To Neutral Position
5 Driving mode 5.2 Operating the transmission 5.2.2 Switching the transmission to neutral position You can switch the transmission to neutral position at any time. Risk of accidents when switching on while driving! If you switch the transmission to neutral position while driving, the drive line will be interrupted.
Page 237: Selecting The Direction Of Travel And Starting Gear
5 Driving mode 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 - 50. direction of travel The following requirements must be met before selecting the direction of travel: –...
Page 238 5 Driving mode 5.2 Operating the transmission For reverse travel The reversing lights, reversing lamps and reversing camera are switched on. The display (1) shows the area behind the truck crane. When you exit transmission mode R, the reversing lamp and camera are switched off and the display (1) shows the CCS menu.
Page 239: Changing The Operating Mode
5 Driving mode 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 operating modes while the vehicle is stationary or while on the move.
Page 240: Starting
5 Driving mode 5.2 Operating the transmission 5.2.5 Starting Danger due to unexpected moving! Also apply the parking brake before starting on slightly sloping ground. The gear is engaged only once you press the accelerator. This can lead to the truck crane starting to move (possibly backwards) while you are moving your foot from the brake pedal to the accelerator.
Page 241: Driving And Changing Gears
5 Driving mode 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 while driving! If while driving in one direction you select a gear for a position other than the current driving direction, the transmission shifts into the neutral position.
Page 242 5 Driving mode 5.2 Operating the transmission In manual In this operating mode, the transmission only shifts gears when you operate the operating mode gearshift lever. Manual upshifting To upshift, you must pull the gearshift lever up briefly: – Shift up a gear: Push up once –...
Page 243: Changing The Driving Direction
5 Driving mode 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 is shown on the display.
Page 244: On The Roller Type Dynamometer
5 Driving mode 5.2 Operating the transmission 5.2.9 On the roller type dynamometer Danger of unexpected moving off the 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 off them.
Page 245: Driving The Truck Crane
5 Driving mode 5.3 Driving the truck crane Driving the truck crane 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 246 5 Driving mode 5.3 Driving the truck crane • Steering Always pay attention to all indicator lamps and all information in this and subsequent sections. Risk of accidents due to truck crane that cannot be steered and leaking oil! If a warning message appears, make sure to follow the instructions in this section and take all the measures specified.
Page 247 5 Driving mode 5.3 Driving the truck crane • Warning Observe all error and warning messages. messages Risk of damage if warning messages are ignored! After warning messages are displayed, always observe all information in the cor- responding section in good time and take appropriate measures to remedy the situation.
Page 248 5 Driving mode 5.3 Driving the truck crane AdBlue (DEF) tank display Never run the AdBlue (DEF) tank completely empty, always refuel in due time; à p. 4 - 8. à If the AdBlue (DEF) tank is empty the torque is reduced; p.
Page 249: Cruise Control
5 Driving mode 5.3 Driving the truck crane 5.3.2 Cruise control Cruise control enables you to drive at a constant speed without pressing the accelerator. Risk of accidents due to carelessness! Be ready to brake at all times when cruise control is switched on. Switch cruise control on only if the traffic situation permits a constant speed.
Page 250: Switching Off
5 Driving mode 5.3 Driving the truck crane Changing the speed – Increase – button (4) – Reduce – button (5) – Continuous change • Keep the button pressed until the desired speed (2) is reached – Step-by-step change • Press the button once.
Page 251: Temposet
5 Driving mode 5.3 Driving the truck crane 5.3.3 Temposet You can use Temposet to limit the maximum speed. You can only switch on Temposet at speeds higher than 15 km/h (9 mph). If Temposet cannot be switched on, the symbol (1) is shown. Pre-selecting •...
Page 252 5 Driving mode 5.3 Driving the truck crane Changing the speed – Increase – button (4) – Reduce – button (5) – In small steps • Press the button once. The speed (2) changes by 1 km/h (0.6 mph). – In large steps •...
Page 253: Driving Downhill
5 Driving mode 5.3 Driving the truck crane 5.3.4 Driving downhill Risk of accidents when driving in neutral position! Never switch to neutral position while driving. In neutral position, the truck crane may accelerate and the engine retarder is ineffective. Starting The engine must be running.
Page 254 5 Driving mode 5.3 Driving the truck crane Inspections when While driving, the engine speed must not exceed 2,300 rpm. The engine speed driving downhill is not limited automatically. Risk of damage due to excessive engine speed! If the maximum permissible engine speed is reached, shift up a gear or slow the truck crane down.
Page 255 5 Driving mode 5.3 Driving the truck crane Additional brakes Engine retarder The truck crane has an engine flap brake that it uses as an engine retarder. The engine retarder only becomes effective at an engine speed of 900 rpm and can be used up to a maximum speed of 2,300 rpm.
Page 256: Driving Uphill
5 Driving mode 5.3 Driving the truck crane 5.3.5 Driving uphill Starting The engine must be running. Danger of the truck crane starting to move in the unexpected direction! When starting to move forwards, always keep the truck crane stationary with the parking brake until the transmission is engaged.
Page 257: Overriding The Torque Reduction
5 Driving mode 5.3 Driving the truck crane 5.3.6 Overriding the torque reduction A torque reduction can occur for various different reasons. – The AdBlue (DEF) supply is used up. – A system malfunction has been detected. Before the torque is automatically reduced, various messages are displayed at the on-board computer, e.g.
Page 258: Cleaning The Exhaust System
5 Driving mode 5.3 Driving the truck crane 5.3.7 Cleaning the exhaust system Risk of burns during the cleaning procedure! The exhaust system can heat to over 600 °C (1,110 °F) during automatic and manual cleaning. Keep away from the exhaust system and ensure that no persons on the carrier are in the vicinity of the exhaust system or exhaust pipe.
Page 259: Manual Cleaning
5 Driving mode 5.3 Driving the truck crane Manual cleaning You must perform manual cleaning if automatic cleaning is not performed in time. Depending on the degree of contamination of the exhaust system, manual clean- ing needs to be performed within a certain time. Appropriate messages are dis- à...
Page 260 5 Driving mode 5.3 Driving the truck crane Disabling cleaning Automatic cleaning cannot be performed and manual cleaning cannot be started when cleaning is disabled. This function is for sites where an exhaust tempera- ture higher than 600 °C (1,110 °F) poses a danger. At normal operating conditions, automatic cleaning is performed without interrupt- ing operation and is the best solution for the exhaust system.
Page 261: Fold-Up Berth
5 Driving mode 5.3 Driving the truck crane 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 belt has engaged and is pulled taut. Put up the back rests of the seats.
Page 262 5 Driving mode 5.3 Driving the truck crane Blank page 5 - 68 3 303 279 en Operating manual GMK5150XL...
Page 263: Off-Road Driving
5 Driving mode 5.4 Off-road driving Off-road driving This section describes settings, connections and procedures for adapting the truck crane’s vehicle handling to off-road conditions. The specified angle of negotiable banks applies with the warning signs folded up. It is recommended to drive off-road with the warning signs folded up; à...
Page 264: Transfer Case - Switching The Off-Road Gear On/Off
5 Driving mode 5.4 Off-road driving 5.4.1 Transfer case – switching the off-road gear on/off The off-road gear increases the thrust of the driven wheels. Prerequisites • Stop the truck crane. • Shift the transmission to neutral position. • Open the menu (1) – Driving menu. (A) –...
Page 265: Longitudinal And Transverse Differential Locks
5 Driving mode 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 / off at the same time.
Page 266: Switching Off
5 Driving mode 5.4 Off-road driving Switching off • Select and confirm the symbol (1) for the – Longitudinal differential locks (A) or – Transverse differential locks (B). Display: – first symbol (2) – yellow, then symbol (3) – green, differential locks off. If symbol (3) is not green then drive back and forth slowly.
Page 267: Operating The Level Adjustment System
5 Driving mode 5.4 Off-road driving 5.4.3 Operating the level adjustment system Fold up the warning signs in order that they are not damaged when lowering the à truck crane; p. 5 - 10. Opening the menu You can use the level adjustment system to set the on-road level, change the overall level and incline the truck crane.
Page 268 5 Driving mode 5.4 Off-road driving Adjusting the For on-road driving, you must always adjust the on-road level in order to adhere on-road level to the specified overall height. • Park the truck crane on a level surface. • Set the steering to straight ahead. •...
Page 269 5 Driving mode 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 the total permissible height! Always bring the truck crane to on-road level before driving on roads after changing the level.
Page 270 5 Driving mode 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.
Page 271: Freeing A Truck Crane Stuck In Terrain
5 Driving mode 5.4 Off-road driving 5.4.4 Freeing a truck crane stuck in terrain Rocking the truck If the truck crane is stuck in terrain, you can try to free it by driving it 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 272 5 Driving mode 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. Pulling out the truck crane abruptly or at an angle may damage the chassis.
Page 273: Separate Steering
5 Driving mode 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 274: Switching To Separate Steering
5 Driving mode 5.5 Separate steering 5.5.1 Switching to separate steering Always switch to separate steering when – Driving with the truck crane rigged or – Steering at low speed Risk of accidents when driving on-road with unlocked steering! After driving with separate steering, change over immediately to normal steering mode.
Page 275 5 Driving mode 5.5 Separate steering Steering with separate steering – automatically • Steer the 1st and 2nd axle lines with the steering wheel. The electronics system measures the steering angle of the 1st and 2nd axle lines and automatically steers the wheels of the 3rd to 5th axle lines correspondingly. (A) –...
Page 276 5 Driving mode 5.5 Separate steering (A) – For driving around corners • Steer the 3rd to 5th axle lines opposite to the 1st and 2nd axle lines. (B) – For crab travel mode • Steer the 3rd to 5th axle lines in the same direction as the 1st and 2nd axle lines.
Page 277: Switching To Normal Steering Mode
5 Driving mode 5.5 Separate steering 5.5.2 Switching to normal steering mode After driving with separate steering, change over immediately to normal steering mode. Switching off the separate steering is possible during a standstill and while driving, up to a speed of about 5 km/h (3 mph). •...
Page 278 5 Driving mode 5.5 Separate steering Blank page 5 - 84 3 303 279 en Operating manual GMK5150XL...
Page 279: Switching Off The Truck Crane
5 Driving mode 5.6 Switching off the truck crane Switching off the truck crane 5.6.1 Every time the truck crane is at a standstill To switch off the truck crane, you must: 1. Stop the truck crane 2. Apply the parking brake à...
Page 280: Every Time When Stationary For More Than 8 Hours
5 Driving mode 5.6 Switching off the truck crane 5.6.2 Every time when stationary for more than 8 hours • Switch off all current consumers, for example, auxiliary heaters. • Switch off the engine, turn the ignition key to position 0 and remove it •...
Page 281: When The Truck Crane Is Stationary For A Longer Period
5 Driving mode 5.6 Switching off the truck crane 5.6.3 When the truck crane is stationary for a longer period In addition to the measures taken for a standstill exceeding 8 hours, you can switch off the battery master switch II – if present. That prevents battery discharge.
Page 282: Secure It Against Moving Away
5 Driving mode 5.6 Switching off the truck crane 5.6.4 Secure it against moving away The number of wheel chocks supplied varies according to the regulations in the country. Risk of accidents due to the truck crane moving unintentionally! On uphill and downhill gradients secure the truck crane using wheel chocks in addition to the parking brake.
Page 283: Heating And Air-Conditioning System
5 Driving mode 5.7 Heating and air-conditioning system Heating and air-conditioning system 5.7.1 Standard heating system • Do not cover the opening (1) in order that air can flow into the passenger cab floor. The operating elements for the standard heating system are only active if the auxiliary water heating system is switched off.
Page 284: Air Distribution
5 Driving mode 5.7 Heating and air-conditioning system Air distribution You can direct the air to flow out of various air vents. Assignment of the air vents – Button (1) – Air vents (A) – Button (2) – Air vents (B) –...
Page 285 5 Driving mode 5.7 Heating and air-conditioning system Adjusting the air vents 1 – Press: Open and direct air flow 2 – Turn: Direct the air flow Setting fresh air/recirculated air – Fresh air Press button (1) repeatedly until the lamp (2) goes out.
Page 286 5 Driving mode 5.7 Heating and air-conditioning system Heating • Turn the switch (2) to the desired position between A and B. • Turn the switch (1) to the desired level, e.g. to level 2. • To heat up faster you can set recirculated air – lamp (4) lights up.
Page 287 5 Driving mode 5.7 Heating and air-conditioning system Switching off Switching off the heating system • Turn the switch (2) as far as it will go, to A (cold). Switching off the ventilation • Turn the switch (1) to level 0. Switching off recirculated air •...
Page 288: Air-Conditioning System
5 Driving mode 5.7 Heating and air-conditioning system 5.7.2 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 not exceed 10 °C to 14 °C (18 °F to 25 °F).
Page 289 5 Driving mode 5.7 Heating and air-conditioning system • Switching on Start the engine. The air-conditioning system only works when the engine is running. à à • Switch off the auxiliary heater; p. 5 - 98, p. 5 - 101. •...
Page 290 5 Driving mode 5.7 Heating and air-conditioning system Drying The air-conditioning is switched on – lamp (1) lights up. • Turn the switch (3) as far as it will go B (warm). • Turn the switch (2) to the desired level, e.g.
Page 291: Switching Off
5 Driving mode 5.7 Heating and air-conditioning system Switching off • Press the button (2) repeatedly until the lamp (1) goes out. Recirculated air is switched off – the lamp (3) goes out. Forced ventilation is switched off. • Set the heating as required; à...
Page 292: Auxiliary Water Heating System
5 Driving mode 5.7 Heating and air-conditioning system 5.7.3 Auxiliary water heating system Risk of explosion when operating the auxiliary heater! Operating the auxiliary heater is not permitted: – At service stations and tank farms – At places where flammable gases or vapours can be found or formed (for example, at places where fuel is stored and in chemical factories), –...
Page 293 5 Driving mode 5.7 Heating and air-conditioning system Setting for preheating the engine • Press the switch next to symbol (1). After switching on the auxiliary water heater, further settings are made automatically. – The lamp (2) lights up – preheating on. –...
Page 294 5 Driving mode 5.7 Heating and air-conditioning system Switching on/off manually The heating system can be operated when the engine is stationary or running. Accelerated discharge of battery when the engine is switched off. The batteries will run flat if you operate the heater with the engine switched off. They will then have to be recharged after shorter periods of time.
Page 295: Auxiliary Air Heater - Driver's Cab
5 Driving mode 5.7 Heating and air-conditioning system 5.7.4 Auxiliary air heater – driver’s cab Risk of explosion when operating the auxiliary heater! Operating the auxiliary heater is not permitted: – At service stations and tank farms – At places where flammable gases or vapours can be found or formed (for example, at places where fuel is stored and in chemical factories), –...
Page 296 5 Driving mode 5.7 Heating and air-conditioning system à • Switch on the ignition; p. 4 - 11. à • Start the engine as required; p. 4 - 3. – Switching on • Press the button (1) – the lamp lights up green. à...
Page 297: Auxiliary Air Heater - Battery
5 Driving mode 5.7 Heating and air-conditioning system 5.7.5 Auxiliary air heater – battery Risk of explosion when operating the auxiliary heater! Operating the auxiliary heater is not permitted: – At service stations and tank farms – At places where flammable gases or vapours can be found or formed (for example, at places where fuel is stored and in chemical factories), –...
Page 298: Audio Device
5 Driving mode 5.8 Audio device à • Switch on the ignition; p. 4 - 11. à • Start the engine as required; p. 4 - 3. – Switching on • Press the button (1) – the lamp lights up green. à...
Page 299: Towing A Trailer
5 Driving mode 5.9 Towing a trailer Towing a trailer For 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 300: Coupling The Trailer
5 Driving mode 5.9 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 301 5 Driving mode 5.9 Towing a trailer Risk of accidents if the trailer is coupled incorrectly! 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 302 5 Driving mode 5.9 Towing a trailer Removing the 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 303 5 Driving mode 5.9 Towing a trailer Risk of injury when manually closing the towbar coupling! When closing, the lever moves down with great force in the direction of the coupling jaw. Start the closing process only by moving the lever briefly in the direction of the coupling jaw with the ball of your hand.
Page 304 5 Driving mode 5.9 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 gradients (e.g. when a brake hose has burst). To check this, you can release the parking brake of the trailer on its own.
Page 305: Driving Modes / Rigging For On-Road Driving
12 t (26,500 lbs). notes that driving with Manitowoc Crane Group Germany GmbH an axle load exceeding 12 t (26,500 lbs) can overheat the brake system and the braking deceleration required by the EU partial type-approval cannot be ensured.
Page 306: Information On How To Use The Tables
6 Driving modes / rigging for on-road driving 6.1 Driving modes 6.1.1 Information on how to use the tables This section only shows some standard driving modes. For further information on additional or individual driving modes, please contact Grove Product Support The tables consist of two parts: –...
Page 307 6 Driving modes / rigging for on-road driving 6.1 Driving modes 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs) à The driving modes are applicable to all engine types; Engine, p. 1 - 17. à Tyres Also observe the effects on the axle loads when towing a trailer;...
Page 308 6 Driving modes / rigging for on-road driving 6.1 Driving modes à Tyres Also observe the effects on the axle loads when towing a trailer; p. 5 - 105. 445/95 R25 Driving Mode ✔ ✔ ✔ ✔ Drive 10 x 6 x 10 ✔...
Page 309 6 Driving modes / rigging for on-road driving 6.1 Driving modes à Tyres Also observe the effects on the axle loads when towing a trailer; p. 5 - 105. 525/80 R25 Driving mode ✔ ✔ Drive 10 x 6 x 10 ✔...
Page 310: Maximum Permitted Speeds With An Axle Load Of Over 12 T (26,500 Lbs)
6 Driving modes / 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 specified here.
Page 311: Weighing The Truck Crane
6 Driving modes / 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 GMK5150XL 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 312 6 Driving modes / 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 at the same level. If for instance only axle group A1 is to be weighed, then axle group A2 must be compensated for on a substructure U that has the same height...
Page 313: Weighing Procedure
6 Driving modes / rigging for on-road driving 6.2 Weighing the truck crane Weighing procedure Perform the weighing procedure only with the crane truck standing on firm and horizontal ground. All scales must be at the same height. • Position the scales W1 to W4 (or the necessary substructure) 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 314 6 Driving modes / rigging for on-road driving 6.2 Weighing the truck crane Evaluation In the example shown you would get four weighing results. Let us 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 the...
Page 315: Rigging Work For Driving With A Dolly
6 Driving modes / 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 on a dolly when driving. For this purpose, the truck crane must be fitted with a slewing gear freewheel, boom floating position and, if necessary, with a boom pre-tensioning device.
Page 316: Switching On The Slewing Gear Freewheel
6 Driving modes / 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 317: Switching On The Boom Floating Position
6 Driving modes / 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 is 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 resting on a dolly.
Page 318: Switching On Boom Pre-Tensioning
6 Driving modes / 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 boom pre-tensioning. •...
Page 319: Raising/Lowering The 3Rd Axle Line
6 Driving modes / rigging for on-road driving 6.3 Rigging work for driving with a dolly 6.3.4 Raising/lowering the 3rd axle line • Open the menu (1) – Suspension/level adjustment menu. Raising • Use the level adjustment system to lower the à...
Page 320 6 Driving modes / rigging for on-road driving 6.3 Rigging work for driving with a dolly Blank page 6 - 16 3 303 279 en Operating manual GMK5150XL...
Page 321: Rigging The Main Boom
6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom Rigging the main boom This section applies only to truck cranes that are equipped with the pulling devices for removing/installing the main boom. Risk of accidents when removing/installing the main boom without pulling devices Only remove or install the main boom if the truck crane is equipped with the factory-installed pulling devices and with the necessary accessories.
Page 322: Checklist: Removing The Main Boom
6 Driving modes / 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 323 6 Driving modes / 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 324 6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom 9. Lift the main boom off the turntable. 10. Place the main boom on the separate vehicle and secure it for transport; à p. 6 - 35. à...
Page 325: Checklist: Installing The Main Boom
6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom 6.4.2 CHECKLIST: Installing the main boom This checklist is not a complete operating manual. There are accompanying operating instructions, which are indicated by cross-references. Observe the warnings and safety instructions specified there! Prerequisites The truck crane is supported by an outrigger span of at least 8.030 m x 2.500 m (26.3 ft x 8.2 ft).
Page 326 6 Driving modes / 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 327 6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom à 10. Establish the hydraulic/electrical 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 328: Establishing/Breaking The Hydraulic/Electrical Connection
6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom 6.4.3 Establishing/breaking the hydraulic/electrical connection Risk of malfunction in the superstructure electronics! Always turn off the ignition in the crane cab before you establish or break the electrical connection. This prevents malfunctions in the electronics and corresponding error messages during subsequent crane operation.
Page 329 6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom Establishing • Remove the plug from the socket (4) and plug it into the dummy socket (3). • Insert the plug (5) into the socket (4). • Connect all hoses (1) to the connections (2).
Page 330: Derricking Cylinder Support
6 Driving modes / 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 331 6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom Marking The lifting gear is marked. Only connect those parts of the lifting gear that have the same marking. Only fasten the lifting gear to the slinging points intended for this purpose.
Page 332 6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom • Insert the bracket (3) into the slinging point (1). Pull the pin (2) • Insert the bracket into the slinging point (4). • Secure the bracket with the pin (2) and the retaining pin.
Page 333: Switching The Pressure Relief On/Off
6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom 6.4.6 Switching the pressure relief on/off The pressure relief prevents the derricking cylinder extending when the engine runs, after the main boom has been removed. When removing •...
Page 334: Pulling/Fitting The Derricking Cylinder Head Axle
6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom 6.4.7 Pulling/fitting the derricking cylinder head axle 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 335 6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom Risk of accidents from falling derricking cylinder! Always take the load off of the derricking cylinder using the lifting device before pulling the head pin. By doing this, you prevent the derricking cylinder falling down, injuring people or being damaged while pulling the head pin.
Page 336: Extending/Retracting The Boom Pivot Pin
6 Driving modes / 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 337 6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom Switching over the hydraulic circuit • Switch over the valves – lever (4) vertical. Releasing the pivot pin • Remove the pins (1) from the connecting points (2) and insert them into the connecting points (3).
Page 338 6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom Pushing the pivot After pushing in, you must secure the pivot pins and switch over the hydraulic pin in circuit. 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 339: Transporting The Main Boom
6 Driving modes / 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 that is of sufficient size and à has sufficient lifting capacity; p. 1 - 11. Risk of damage to the main boom! Always place the main boom on a suitable substructure.
Page 340: Aligning The Connecting Points
6 Driving modes / 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 341: Checks After Installing The Main Boom
6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom 6.4.12 Checks after installing the main boom • Check to see if the pressure relief is switched off and is secured with the lock; à p. 6 - 29. •...
Page 342 6 Driving modes / rigging for on-road driving 6.4 Rigging the main boom Blank page 6 - 38 3 303 279 en Operating manual GMK5150XL...
Page 343: Removing/Installing The Outrigger Beams
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams Removing/installing the outrigger beams To rig the outrigger beams, the outriggers must be fitted with hydraulic connections (1) that can be separated. During rigging, each outrigger beam is removed and mounted as a complete “package”, consisting of inner and outer outrigger beams, cylinders and add-on parts.
Page 344: Checklist: Removing The Outrigger Beams
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.1 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 given there! à...
Page 345 6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams à 6. Separate the connections to the supporting box; p. 6 - 52. 7. Sling the outrigger beam and pull it out of the supporting box until it reaches à...
Page 346: Checklist: Installing The Outrigger Beams
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.2 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 given there! à...
Page 347 6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams à 6. Screw in the spacers; p. 6 - 50 à 7. If necessary, position outrigger pads; p. 6 - 46. 8. Install all necessary outrigger beams in the same way in accordance with this checklist.
Page 348: Centre Of Gravity Data
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.3 Centre of gravity data The information in this section refers 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 349: Preparations - On The Truck Crane
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.5 Preparations – on the truck crane Prerequisites The following requirements must be met for installing/removing the outrigger beams: – All rigging work that involves slewing the superstructure has been completed. –...
Page 350: Removing/Attaching Outrigger Pads
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.6 Removing/attaching outrigger pads You only need remove the outrigger pads if the outrigger beams are to be transported lying on their side. For transport in a suitable holding frame, the outrigger beams can be set down on the outrigger pad.
Page 351 6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams Attaching the After installing the outrigger beam, you must attach the outrigger pad. outrigger pad • (A) – Remove the pins (1). • Extend the supporting cylinder far enough so that the bearing surface (3) is below the guide (2).
Page 352: Disconnecting/Establishing The Hydraulic Connection
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.7 Disconnecting/establishing the 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. Removing the connection Always separate all connections (4).
Page 353: Removing/Establishing The Electrical Connection
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.8 Removing/establishing the electrical connection The electrical connection is only present on truck cranes equipped with an outrigger pressure display or outrigger span monitoring system. Danger of malfunctions in the electronic system! Always turn off the ignition before you remove or establish the electrical connec- tion.
Page 354: Unscrewing/Screwing In The Spacers
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.9 Unscrewing/screwing in the spacers There are two spacers for each outrigger beam – In the supporting box and – in the outrigger beam on the opposite side. The illustrations show as an example the spacers for the outrigger beam on the front right side.
Page 355 6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams Screwing in Before you retract/extend an outrigger beam after installation, you must screw in the spacers. At the supporting box • Screw in the bolts (1) until the spacers (3) touch the outrigger beam (4) at the top.
Page 356: Separating/Establishing The Connections To The Supporting Box
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.10 Separating/establishing the connections to the supporting box The illustrations show the connecting point for the front right outrigger beam as an example. (A) – Separating the connection •...
Page 357 6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams • Fasten lifting gear (1) and a chain hoist. • Pull the outrigger beam out so far that the centre of gravity (2) is accessible; à Centre of gravity data, p. 6 - 44. •...
Page 358 6 Driving modes / rigging for on-road driving 6.5 Removing/installing 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 swinging outrigger beam! Do not guide the outrigger beam with your hands when inserting it.
Page 359 6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams • Lift the outrigger beam as far as possible into the supporting box. Correct the height so that it does not remain hanging on the edges (1). •...
Page 360: Transporting The Outrigger Beams
6 Driving modes / rigging for on-road driving 6.5 Removing/installing the outrigger beams 6.5.12 Transporting the outrigger beams • For transport, only use a separate vehicle with sufficient load bearing capacity. à Transport dimensions and weight; p. 1 - 11. •...
Page 361: Transport
7 Transport 7.1 Transport with transport vehicle Transport Transport should only be carried out by qualified heavy transport companies whose personnel are well-acquainted with loads of these dimensions and weights. Transport with transport vehicle Risk of accidents due to improper transport! Assign transport to qualified companies only and ensure that the regulations applicable in the country in which you are working are adhered to.
Page 362: Checklist: Checks Before Transport
7 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 given there! 1. – All telescopic sections are interlocked; the telescoping cylinder is locked with telescopic section I .
Page 363 7 Transport 7.1 Transport with transport vehicle 6. Anemometer, air traffic control light and camera system are removed: à Anemometer and air traffic control light, p. 12 - 164, à Camera on the main boom, p. 12 - 173. à 7.
Page 364 7 Transport 7.1 Transport with transport vehicle 11. The hook block is à – attached to the bumper; p. 12 - 137 or à – unreeved; Unreeving the hoist rope, p. 12 - 149. à 12. The transverse differential locks are switched on; p.
Page 365: Driving The Truck Crane On To The Transport Vehicle
7 Transport 7.1 Transport with transport vehicle 7.1.2 Driving the truck crane on to the transport vehicle Risk of accidents due to inadequate field of vision! Always have a banksman on hand to help when driving on to a transport vehicle. Maintain eye contact or radio contact with the banksman at all times while driving on to the transport vehicle.
Page 366: Securing The Truck Crane Against Slipping
7 Transport 7.1 Transport with transport vehicle 7.1.3 Securing the truck crane against slipping Risk of accidents due to falling parts! Only use suitable lifting gear with sufficient load bearing capacity and only use the slinging points provided. • Secure the truck crane with the chocks (1). •...
Page 367: Stopping The Truck Crane For Transport
7 Transport 7.1 Transport with transport vehicle 7.1.4 Stopping the truck crane for transport Before transport, carry out the same steps that are required for a standstill period à exceeding 8 hours; Every time when stationary for more than 8 hours, p. 5 - 86. If the truck crane is equipped with a battery master switch II , you can switch it off for transport to spare the batteries.
Page 368 7 Transport 7.1 Transport with transport vehicle Blank page 7 - 8 3 303 279 en Operating manual GMK5150XL...
Page 369: Malfunctions In Driving Mode
8 Malfunctions in driving mode 8.1 Emergency stop switches Malfunctions in driving mode Emergency stop switches Four emergency stop switches are provided for emergencies: 1 On the carrier – always active (on both sides) 2 Only active with connected hand-held con- trol –...
Page 370: What To Do In The Event Of Malfunctions
8 Malfunctions in driving mode 8.2 What to do in the event of malfunctions What to do in the event of malfunctions 8.2.1 What to do when a malfunction occurs in road traffic If the truck crane can no longer be driven due to an accident or another malfunc- tion, observe the following.
Page 371: Warning And Error Messages
8 Malfunctions in driving mode 8.3 Warning and error messages Warning and error messages • Always note down the number of the program version and the serial number after a malfunction occurs before contacting Grove Product Support The crane type (1) and the serial number (2) are shown in the start menu. à...
Page 372 8 Malfunctions in driving mode 8.3 Warning and error messages In range 1 Steering circuits warning If one or more lamps (1) light up while driving. Note – The lamp for steering circuit 3 only goes out at a speed of over about 10 km/h (6 mph).
Page 373 8 Malfunctions in driving mode 8.3 Warning and error messages Steering malfunction The lamp (1) lights up – on the CCS display symbol (2) yellow. – The lamp (1) only lights up briefly and then goes out. Error with low priority; continued driving possible. •...
Page 374: Engine Malfunction
8 Malfunctions in driving mode 8.3 Warning and error messages • Briefly switch the ignition off and then on again. If the error is still present, then check the steering angle at the 3rd axle line and at the 4th axle line. Whether it is possible to continue driving must be decided based on the current situation.
Page 375: Warning And Fault Messages On The On-Board Computer
8 Malfunctions in driving mode 8.3 Warning and error messages 8.3.2 Warning and fault messages on the on-board computer Risk of damage if messages are disregarded! For all messages, always take note of the text shown. Follow the requests to stop immediately, taking the traffic situation into account. Complete the remedial measures shown, and described here, in good time.
Page 376: Acknowledging Messages
8 Malfunctions in driving mode 8.3 Warning and error messages Acknowledging messages • Press the button (3) once – the message in area (1) goes out. The corresponding symbols are displayed (2) until the cause of the message has been eliminated.
Page 377: Engine Messages
8 Malfunctions in driving mode 8.3 Warning and error messages Engine messages Red message – symbol (1) is displayed Text: Engine oil pressure too low Stop vehicle and shut down engine • Stop the truck crane under consideration of the current traffic situation. •...
Page 378 8 Malfunctions in driving mode 8.3 Warning and error messages Red message – symbol (1) is displayed Text: Coolant level too low Top up coolant • Stop the truck crane under consideration of the current traffic situation. • Apply the parking brake and switching off the engine. à...
Page 379 8 Malfunctions in driving mode 8.3 Warning and error messages Yellow message – symbol (1) is displayed Text: Engine malfunction • At least one system malfunction listed. – Engine – Engine cooling system – Engine control system – Fuel system •...
Page 380 8 Malfunctions in driving mode 8.3 Warning and error messages Yellow message – symbol (1) and symbol (2) are displayed Text: AdBlue reserve Please top up AdBlue Reduction of engine output pending If the AdBlue level continues to drop, there will be a torque reduction. à...
Page 381 8 Malfunctions in driving mode 8.3 Warning and error messages Exhaust system In case of messages concerning the exhaust system, additional lamps are active messages on the Centre control unit. If you do not observe the information on the on-board computer and do not take appropriate measures, then this can result in damage in the exhaust system and to restrictions in operation.
Page 382 8 Malfunctions in driving mode 8.3 Warning and error messages Yellow message – symbol (1) is displayed, lamp (2) flashes yellow Text: Fuel particle filter full Initiate regeneration immediately à • Start manual cleaning immediately; p. 5 - 65. Red message – symbol (1) is displayed, lamp (2) lights up red Text: Fuel particle filter full Stop vehicle, contact Service, regeneration no longer possible...
Page 383: Transmission Messages
8 Malfunctions in driving mode 8.3 Warning and error messages Transmission messages Red message – symbol (1) is displayed Text: Clutch malfunction Stop vehicle and contact Service • While paying attention to the current traffic situation, stop driving and apply the parking brake.
Page 384 8 Malfunctions in driving mode 8.3 Warning and error messages Yellow message – symbol (1) is displayed Text: Transmission/clutch supply pressure too low • While paying attention to the current traffic situation, stop driving and apply the parking brake. à •...
Page 385: Brake System Messages
8 Malfunctions in driving mode 8.3 Warning and error messages Grey message – symbol (1) is displayed Text: Clutch severely loaded Temperature in the clutch very high. If the cause is not eliminated, clutch damage could result. • Only start in 1st gear if possible. •...
Page 386 8 Malfunctions in driving mode 8.3 Warning and error messages Message – symbol (1) is displayed Engine retarder malfunction The braking performance can change. • If stopping is not possible directly, drive particularly carefully at reduced speed. The braking performance can change abruptly! •...
Page 387 8 Malfunctions in driving mode 8.3 Warning and error messages Message – symbol (1) is displayed with (2) or (3) or (4) After switching on the ignition, symbols (1) and (2) are displayed briefly. If symbols are displayed permanently, the ABS system is not available. If there is an electronic malfunction at the ABS system, an additional text is displayed –...
Page 388 8 Malfunctions in driving mode 8.3 Warning and error messages Yellow message – symbol (1) (one or both displays). Text: Undervoltage Stop vehicle and shut down engine Contact Service and vehicle performance changed The battery charge level is too low. Vehicle handling and the braking performance may change! –...
Page 389: Maintenance Messages
8 Malfunctions in driving mode 8.3 Warning and error messages Yellow message – symbol (1) and symbol (2) are displayed Text: Turn signal indicator malfunction The turn signal indicator on the trailer has a malfunction. • Replace the faulty light immediately or find a repair shop. Maintenance messages Grey message –...
Page 390: Various Messages
8 Malfunctions in driving mode 8.3 Warning and error messages Various messages Yellow message – symbol (1) is displayed The fuel tank is in the reserve range. à • Refuel as soon as possible; Refuelling, p. 4 - 7. Grey message – symbol (1) is displayed The windscreen washing system tank is almost empty.
Page 391: Warning Messages On The Ccs Display
8 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 deviate from a target value If CCS detects a warning or a fault then a symbol is displayed in the display area (1).
Page 392 8 Malfunctions in driving mode 8.3 Warning and error messages Symbols on the CCS display Symbol Cause Remedy Details / effect Engine oil pressure too low Danger of damage to the engine! Due to the current situation, stop operation and switch off the engine Possibly also additional displays/error messages and warning buzzer...
Page 393 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Coolant level too low After driving – top up the coolant. If the message appears again – notify and have the fault recti- Grove Product Support fied Engine preheating active Engine start disabled...
Page 394 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Supply pressure too low The supply pressure in the Before driving – build up supply pressure. compressed air system is below While driving – while paying attention to the approx.
Page 395 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect External system error (red) Error message from external system Under consideration of the current situation, stop (e.g. engine, transmission) operation Error message stored in the Check the error messages and acknowledge the à...
Page 396 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Transfer case oil pressure too low Danger of damage to the Due to the current situation, stop operation and transmission switch off the engine Some additional displays are also Check the oil level and top up if necessary active...
Page 397 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Hydraulic oil too hot Hydraulic oil temperature above 80 °C – When driving (176 °F) Reduce power and interrupt operation at the next opportunity. Danger of overheating! Allow the engine to run until the oil has cooled Error message stored in the Crane...
Page 398 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Angle gear oil temperature (red) Maximum permissible oil temperature Due to the current situation, stop operation and exceeded. switch off the engine Danger of damage to the Allow the angle gear to cool down transmission Angle gear oil temperature (yellow)
Page 399 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Torque reduction active (red) Less than 50% of the power still Due to the current situation, stop operation and available switch off the engine Some operations restricted!! Check the additional displays/warning messages and notify...
Page 400 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Air intake inhibitor – perform function test (red) Function test is overdue Perform a function test as soon as possible; à Maintenance manual Air intake inhibitor – perform function test (yellow) Function test is due Perform a function test within one week;...
Page 401 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Driver's cab not locked The driver's cab can tilt forwards Lock the driver's cab when braking! Main boom not set down The main boom is not resting in the Set down the main boom on the boom rest boom rest Risk of accidents by exceeding the...
Page 402 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Cruise control – Grey – ready for operation – Black – switched on Transmission retarder active The transmission retarder has been Switch off the transmission retarder when it is no switched on longer required Hydraulic emergency operation is active...
Page 403 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Anemometer not connected Anemometer input signal interrupted Query the local weather service for wind speed predictions at the site. No current wind speed display available! Have the error rectified at the next opportunity and notify...
Page 404 8 Malfunctions in driving mode 8.3 Warning and error messages Symbol Cause Remedy Details / effect Heating tank below the crane cab is almost empty à Level below approx. 7 l (1.85 gal) Refuel before the fuel is used up; p.
Page 405: Error Messages On The Ccs Display
8 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 system may only be repaired by trained and qualified personnel. • If an error message appears, stop while paying attention to the traffic situation; à...
Page 406 8 Malfunctions in driving mode 8.3 Warning and error messages Error message display For each error there is – The error code (3), – The symbols for the faulty component: Engine Transmission • Always note the error code before contacting Grove Product Support Exit menu You can exit the Engine/transmission errors menu at any time.
Page 407: Troubleshooting
8 Malfunctions in driving mode 8.4 Troubleshooting Troubleshooting This section only deals with malfunctions not displayed by the control. If a warning message or error message is displayed, then observe the information in the corresponding section. In area (1) à Warning messages on the CCS display, p.
Page 408: Malfunctions In The Transmission
8 Malfunctions in driving mode 8.4 Troubleshooting Malfunction Cause Remedy à Engine does not start Emergency stop switch actu- Resetting the emergency stop ated switch, p. 4 - 20 Truck crane driving at A locking procedure is not yet Lock the differential locks or maximum 20 km/h (12 mph) completed steering...
Page 409: Malfunctions Of The Differential Locks
8 Malfunctions in driving mode 8.4 Troubleshooting 8.4.3 Malfunctions of the differential locks Malfunction Cause Remedy Differential locks cannot be Current speed above about Slow down or stop the truck switched on 5 km/h (3 mph) crane Drive train under tension Drive truck crane slowly back and forth in a straight line à...
Page 410: Malfunctions Of The Steering
8 Malfunctions in driving mode 8.4 Troubleshooting 8.4.5 Malfunctions of the steering Malfunction Cause Remedy Steering wheel hard to turn, Oil level in the hydraulic oil tank Check the hydraulic oil level; à creaking noises when too low Maintenance manual. steering Then drive at low speed to the nearest repair shop and have...
Page 411: Malfunctions In The Hydraulic System/Hydraulic Oil Cooler
8 Malfunctions in driving mode 8.4 Troubleshooting 8.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler Malfunction Cause Remedy Hydraulic oil temperature Faulty temperature sensor in the Have the temperature sensor above 80 °C (176 °F), fan in circuit of the hydraulic system, replaced the hydraulic oil cooler not error message is displayed...
Page 412: Emergency Operation And Breakdown Assistance
8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Emergency operation and breakdown assistance 8.5.1 Externally starting the truck crane • Start the engine of the auxiliary vehicle. • Connect the cable (1) to the power supply (24 V) of the auxiliary vehicle. •...
Page 413: Battery Charger
8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.2 Battery charger Prerequisites – The engine has been stopped and secured against unauthorised use, – An external 230 V power supply is available at the location, – The location is well ventilated and protected against moisture. Risk of explosion when operating the battery charger! The battery charger must not be operated: –...
Page 414: Towing Away The Truck Crane
8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.3 Towing away the truck crane Observe the following if the truck crane has to be towed away: – The truck crane may only be towed away with a tow-rod. Attach the tow-rod to the tow-rod coupling on the front bumper.
Page 415: Compressed-Air Supply
8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Compressed-air supply If the engine fails, the truck crane must be supplied with compressed air by the towing vehicle so that the brake system is still supplied with compressed air. •...
Page 416: Final Drives
8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Final drives • Switch off all differential locks. The symbols (1) and (2) must be green, à – Transverse differential locks p. 5 - 71, à – Longitudinal differential lock; p.
Page 417 8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Towing the truck crane out of the danger area Once you have made all the adjustments as described in this section, you can tow the truck crane away from the danger area. •...
Page 418: Wheel Change
8 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 following traffic into account, and secure the truck crane as outlined in the applicable legal stipulations of the country in which you are working.
Page 419 8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance à • Removing a Switch off the suspension; p. 5 - 19. damaged wheel • Raise the truck crane with the outriggers until the wheel to be changed just barely leaves the ground.
Page 420: Mounting A Wheel
8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Additional rear light If there is an additional rear light, then you must remove it before removing the wheel from the spare wheel holder. Before driving on the road, the additional rear light must be reattached.
Page 421 Check the wheel rim, tyres, wheel nuts and wheel studs for damage before mounting the spare wheel. Damaged parts may not be mounted! Only mount the original wheel supplied by Manitowoc Crane Group Germany or an approved wheel of the same size and load bearing capacity! GmbH •...
Page 422: Inflating The Tyres Yourself
8 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 423 8 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 424: Emergency Operation For Steering 3Rd And 4Th Axle Line
8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.6 Emergency operation for steering 3rd and 4th axle line 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 is locked. This axle line can then no longer be steered from the driver's cab or from the crane cab.
Page 425 8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Applying If the current situation allows it, you can slightly lift the mobile crane with the emergency support to relieve the axle line. operation For the operation, you must –...
Page 426 8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Risk of crushing due to turning wheels! Make sure 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 427 8 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 continuous operation for all valves (1). – For the 4th axle line •...
Page 428 8 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Blank page 8 - 60 3 303 279 en Operating manual GMK5150XL...
Page 429: Tilting/Lowering The Driver's Cab
8 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 hydraulic emergency operation to à...
Page 430: Tilting/Lowering The Driver's Cab
8 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab 8.6.2 Tilting/lowering the driver's cab Operating the The driver's cab is tilted and lowered using a hand pump. The lever for the hand hand pump pump is below the seats or in the tool box. •...
Page 431 8 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 432 8 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 433 8 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab Risk of accidents if the driver's cab is not locked! Make sure that the driver's cab is locked afterwards every time it is lowered. This prevents the driver's cab tilting forwards when braking. •...
Page 434 8 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab Blank page 8 - 66 3 303 279 en Operating manual GMK5150XL...
Page 435: Fuses On The Carrier
8 Malfunctions in driving mode 8.7 Fuses on the carrier Fuses on the carrier The fuses are divided into groups and are to be found at various points on the carrier: – In the driver's cab, – In the battery box. Notes on The positions of the fuses, their designations and which functions are protected changing fuses...
Page 436: Fuses In The Driver's Cab
8 Malfunctions in driving mode 8.7 Fuses on the carrier 8.7.1 Fuses in the driver's cab Fuse groups F and A are in the driver's cab. Fuse groups F à Fuse groups A; p. 8 - 71. • Remove the cover (1). Fuse groups F1 to F5 consist of eight fuses each.
Page 437 8 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function F2/1 Control unit UB 1 IOL 32 F2/2 Control unit UB 1 IOL 32 F2/3 Control unit UB 2 IOL 32 F2/4 Control unit UB 2 IOL 32 F2/5 Control unit UB 1 IOL 33 F2/6...
Page 438 8 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function F4/1 Terminal 15 – steering system SLC01 F4/2 Terminal 15 – rotating beacon Terminal 15 – steering system SLC02 F4/3 Monitoring of Boom not set down Terminal 15 –...
Page 439 8 Malfunctions in driving mode 8.7 Fuses on the carrier Fuse groups A à Fuse groups F; p. 8 - 68. • Remove the cover (1). Fuse groups A1 to A5 consist of eight fuses each. A1 Fuses F1 to F5 A2 Fuses F6 to F10 A3 Fuses F11 to F26 A4 Fuses F27 to F42...
Page 440 8 Malfunctions in driving mode 8.7 Fuses on the carrier Fuse group A2 Designation Amperage (A) Function Unassigned Unassigned Terminal 30 – transmission retarder control USB socket Brake light Fuse group A3 Designation Amperage (A) Function Terminal 30 – audio device Terminal 30 -CPC4 Gateway / tachograph 12 V voltage transformer...
Page 441 8 Malfunctions in driving mode 8.7 Fuses on the carrier Fuse group A4 Designation Amperage (A) Function – Unassigned Window winder, driver's door – Unassigned Window winder, passenger door – Unassigned – Unassigned – Unassigned 24 V socket – Unassigned Terminal 15 –...
Page 442: Fuses In The Battery Box
8 Malfunctions in driving mode 8.7 Fuses on the carrier 8.7.2 Fuses in the battery box Fuses F7 to F20 are to be found in the battery box. Danger from lead and lead compounds on batteries! Battery poles, terminals and parts of the battery itself contain lead and lead compounds.
Page 443: Operating Elements For Crane Operation
9 Operating elements for crane operation 9.1 Overview – Notes Operating elements for crane operation All operating elements for driving are described in Chapter 3. This operating manual contains illustrations of the GMK5150L-1 with five telescopic sections. The GMK5150XL has six telescopic sections (1). The illustrations have only been modified where relevant for operation.
Page 444: Overview - Exterior Of The Truck Crane
9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane Overview – Exterior of the truck crane 9 - 2 3 303 279 en Operating manual GMK5150XL...
Page 445 9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane à 1 – Camera on the main boom p. 12 - 173 à – Cameras on the hoists p. 12 - 173 à – Camera on the driver's cab p.
Page 446 9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane 9 - 4 3 303 279 en Operating manual GMK5150XL...
Page 447 9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane 19 Step on the crane cab à – Automatic operation p. 12 - 178 à – Manual operation p. 12 - 179 à 20 Crane cab p.
Page 448: Hand-Held Control
9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane 9.2.1 Hand-held control à 1 Engine control panel p. 9 - 159 à 2 Pre-select emergency operation p. 9 - 160 à 3 Function buttons p. 9 - 160 4 No function à...
Page 449: Outrigger Control Units
9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane 9.2.2 Outrigger control units Menu with This function of the illustrated buttons is the same in all the menus. This function independent of the other buttons depends on the opened menu. buttons à...
Page 450 9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane Outrigger menu 9 - 8 3 303 279 en Operating manual GMK5150XL...
Page 451 9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane Opposite means: on the side of the carrier opposite 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 452 9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane Raise axle menu à 1 to 5 Pre-selection display p. 9 - 115 Directional indicator à Wheel load display, opposite p. 9 - 116 à Wheel load display, operator's side p.
Page 453 9 Operating elements for crane operation 9.2 Overview – Exterior of the truck crane Blank page Operating manual 3 303 279 en 9 - 11 GMK5150XL...
Page 454: Overview Of Crane Cab
9 Operating elements for crane operation 9.3 Overview of crane cab Overview of crane cab 9 - 12 3 303 279 en Operating manual GMK5150XL...
Page 455 9 Operating elements for crane operation 9.3 Overview of crane cab à 1 Side panel operating elements p. 9 - 16 2 Sun visor à 3 Monitor p. 12 - 176 à 4 Current degree of utilisation display p. 11 - 51 à...
Page 456 9 Operating elements for crane operation 9.3 Overview of crane cab 9 - 14 3 303 279 en Operating manual GMK5150XL...
Page 457 9 Operating elements for crane operation 9.3 Overview of crane cab à 16 Service brake p. 9 - 170 17 Accelerator à 18 USB sockets p. 9 - 154 à 19 Left-hand control panel p. 9 - 22 à 20 Right-hand control panel p.
Page 458: Side Panel Operating Elements
9 Operating elements for crane operation 9.3 Overview of crane cab 9.3.1 Side panel operating elements 9 - 16 3 303 279 en Operating manual GMK5150XL...
Page 459 9 Operating elements for crane operation 9.3 Overview of crane cab à 1 Applying/releasing the parking brake p. 9 - 171 à 2 – Starting the engine p. 9 - 97 à – Setting the idling speed p. 9 - 97 3 RCL override –...
Page 460: Rear Operating Elements
9 Operating elements for crane operation 9.3 Overview of crane cab 9.3.2 Rear operating elements 9 - 18 3 303 279 en Operating manual GMK5150XL...
Page 461 9 Operating elements for crane operation 9.3 Overview of crane cab 1 Sun roller blind à 2 Panel operating elements p. 9 - 21 à 3 Cab lighting p. 9 - 157 1), 3) 4 Audio device 5 Loudspeaker 6 Storage compartment à...
Page 462 9 Operating elements for crane operation 9.3 Overview of crane cab Blank page 9 - 20 3 303 279 en Operating manual GMK5150XL...
Page 463 9 Operating elements for crane operation 9.3 Overview of crane cab Panel operating elements à 1 Heating system p. 9 - 28 à 2 Spotlight II on/off p. 9 - 156 à 3 24 V socket p. 9 - 154 à...
Page 464: Control Panel Operating Elements
9 Operating elements for crane operation 9.3 Overview of crane cab 9.3.3 Control panel operating elements Left 9 - 22 3 303 279 en Operating manual GMK5150XL...
Page 465 9 Operating elements for crane operation 9.3 Overview of crane cab à 1 Moving the outrigger p. 9 - 111 à 2 Slewing gear on/off p. 9 - 127 à 3 – Lifting limit switch override p. 9 - 124 à...
Page 466 9 Operating elements for crane operation 9.3 Overview of crane cab Right 9 - 24 3 303 279 en Operating manual GMK5150XL...
Page 467 9 Operating elements for crane operation 9.3 Overview of crane cab à 1 Jog dial (rotary push button) p. 9 - 103 à 2 Main hoist on/off p. 9 - 123 à 3 Derricking gear on/off p. 9 - 129 à...
Page 468: Control Lever Configuration
9 Operating elements for crane operation 9.3 Overview of crane cab 9.3.4 Control lever configuration The truck crane can be equipped with two different control lever configurations. The current configuration of the control levers is indicated by symbols. The symbols are on the panels (1). Version 1 With version 1, the left control lever is configured with the Telescope function.
Page 469: Right Control Lever
9 Operating elements for crane operation 9.3 Overview of crane cab Version 2 With version 2, the right control lever is configured with the Telescope function. Left control lever Right control lever 1 Slew anti-clockwise Raise/retract 2 Slew clockwise Lower/extend 3 Lower auxiliary hoist Lower main hoist 4 Raise auxiliary hoist...
Page 470: Heating And Air-Conditioning System Operating Elements
9 Operating elements for crane operation 9.3 Overview of crane cab 9.3.5 Heating and air-conditioning system operating elements 9 - 28 3 303 279 en Operating manual GMK5150XL...
Page 471 9 Operating elements for crane operation 9.3 Overview of crane cab à (A) – UniControl control unit p. 11 - 162 1 Display 2 Jog dial 3 On/Off switch with lamp à (B) – Heating and air-conditioning system p. 11 - 155 à...
Page 472: Crane Control Operating Elements
9 Operating elements for crane operation 9.4 Crane control operating elements Crane control operating elements 9.4.1 CCS control unit 9 - 30 3 303 279 en Operating manual GMK5150XL...
Page 473 9 Operating elements for crane operation 9.4 Crane control operating elements à 1 CCS display p. 9 - 103 à Overview start menu p. 9 - 33 2 Jog dial (rotary push button) à 3 Exit menu/input mode p. 9 - 106 à...
Page 474: Ccs - Menu-Dependent Displays
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.2 CCS – menu-dependent displays à 1 Slewing gear p. 9 - 127 à 2 Telescoping mechanism p. 9 - 131 à 3 Derricking gear p. 9 - 129 à...
Page 475: Ccs - Start Menu
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.3 CCS – Start menu à 1 RCL display p. 9 - 34 à 2 Engine speed display p. 10 - 10 à 3 AdBlue (DEF) level display p. 10 - 10 à...
Page 476 9 Operating elements for crane operation 9.4 Crane control operating elements RCL display à 1 Slewing ranges/working radii display p. 9 - 35 à 2 Current working radius display p. 9 - 143 à 3 Current slewing angle display p. 9 - 143 à...
Page 477 9 Operating elements for crane operation 9.4 Crane control operating elements Slewing ranges/ working radii display A For the Standard slewing range type B For the MAXbase slewing range type à Current slewing range divisions display p. 9 - 142 à...
Page 478: Ccs - Overview Of Menu Groups
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.4 CCS – Overview of menu groups 9 - 36 3 303 279 en Operating manual GMK5150XL...
Page 479 9 Operating elements for crane operation 9.4 Crane control operating elements à 1 Superstructure menu group p. 9 - 40 – Superstructure lock menu – Counterweight menu à 2 Outriggers/driving menu group p. 9 - 43 – Outrigger menu – Driving menu –...
Page 480 9 Operating elements for crane operation 9.4 Crane control operating elements 9 - 38 3 303 279 en Operating manual GMK5150XL...
Page 481 9 Operating elements for crane operation 9.4 Crane control operating elements à 8 Settings menu group p. 9 - 77 – Crane cab menu – Set display brightness and date/time menu – Switch over units menu – Control lever characteristic curve menu –...
Page 482: Superstructure Menu Group
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.5 Superstructure menu group à 1 Superstructure lock menu p. 9 - 41 à 2 Counterweight menu p. 9 - 42 9 - 40 3 303 279 en Operating manual GMK5150XL...
Page 483 9 Operating elements for crane operation 9.4 Crane control operating elements Superstructure lock menu à 1 Slewing enabled display – identical to the display in the p. 9 - 42 Counterweight menu à 2 Houselock locking status displays p. 9 - 140 à...
Page 484 9 Operating elements for crane operation 9.4 Crane control operating elements Counterweight menu à 1 Slewing enabled display p. 9 - 122 à 2 Display of slewing direction for automatic mode p. 9 - 119 à 3 Current slewing angle display p.
Page 485: Outriggers/Driving Menu Group
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.6 Outriggers/driving menu group 1 Outrigger menu à – Outrigger beam menu p. 9 - 44 à – Outrigger cylinders menu p. 9 - 46 à 2 Driving menu p.
Page 486 9 Operating elements for crane operation 9.4 Crane control operating elements Outrigger menu Outrigger beam menu 9 - 44 3 303 279 en Operating manual GMK5150XL...
Page 487 9 Operating elements for crane operation 9.4 Crane control operating elements à 1 Slewing gear/movements locked display p. 9 - 109 à 2 Parking brake/movements disabled display/warning p. 9 - 110 à 3 Suspension on/off display/warning p. 9 - 109 à...
Page 488 9 Operating elements for crane operation 9.4 Crane control operating elements Outrigger cylinders menu 9 - 46 3 303 279 en Operating manual GMK5150XL...
Page 489 9 Operating elements for crane operation 9.4 Crane control operating elements à 1 Slewing gear/movements locked display p. 9 - 109 à 2 Parking brake/movements disabled display/warning p. 9 - 110 à 3 Suspension on/off display/warning p. 9 - 109 à...
Page 490 9 Operating elements for crane operation 9.4 Crane control operating elements Driving menu 9 - 48 3 303 279 en Operating manual GMK5150XL...
Page 491 9 Operating elements for crane operation 9.4 Crane control operating elements à 1 Transmission mode RM p. 9 - 168 à 2 Transmission mode R p. 9 - 167 à 3 Neutral position N p. 9 - 167 à 4 Transmission mode D p.
Page 492 9 Operating elements for crane operation 9.4 Crane control operating elements Exhaust system menu A Only for EU Tier IV à 1 Override torque reduction p. 9 - 99 B Only for EU Tier V à 1 Override torque reduction p.
Page 493 9 Operating elements for crane operation 9.4 Crane control operating elements Air intake inhibitor menu 1 Close air intake inhibitor à 2 Air intake inhibitor p. 9 - 101 3 Air intake inhibitor maintenance à Only for check that it is functioning; Maintenance manual Operating manual 3 303 279 en...
Page 494 9 Operating elements for crane operation 9.4 Crane control operating elements Blank page 9 - 52 3 303 279 en Operating manual GMK5150XL...
Page 495: Rcl/Telescoping Menu Group
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.7 RCL/Telescoping menu group à 1 Rigging mode/Telescope status input menu p. 9 - 54 à 2 Lifting capacity tables menu p. 9 - 60 à 3 Semi-automatic telescoping menu p.
Page 496 9 Operating elements for crane operation 9.4 Crane control operating elements Rigging mode/ – For the Standard slewing range type Telescope status input menu A For the Main boom boom system B For the Lattice extension boom system 9 - 54 3 303 279 en Operating manual GMK5150XL...
Page 497 9 Operating elements for crane operation 9.4 Crane control operating elements à 1 Enter slewing range p. 9 - 145 à 2 Enter outrigger span p. 9 - 148 à Outrigger span monitoring display p. 9 - 149 à 3 Enter counterweight p.
Page 498 9 Operating elements for crane operation 9.4 Crane control operating elements – For the MAXbase slewing range type Additional equipment 9 - 56 3 303 279 en Operating manual GMK5150XL...
Page 499 9 Operating elements for crane operation 9.4 Crane control operating elements à 1 Enter slewing range p. 9 - 145 à 2 Input of front left outrigger span p. 9 - 148 à 3 Input of front right outrigger span p.
Page 500 9 Operating elements for crane operation 9.4 Crane control operating elements Pre-selection telescoping menu 9 - 58 3 303 279 en Operating manual GMK5150XL...
Page 501 9 Operating elements for crane operation 9.4 Crane control operating elements Enter desired parameter à 1 Input of load p. 9 - 150 à 2 Input of working radius p. 9 - 150 à 3 Input of main boom length p.
Page 502 9 Operating elements for crane operation 9.4 Crane control 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 503 9 Operating elements for crane operation 9.4 Crane control operating elements Semi-automatic telescoping menu à 1 Telescopic sections display p. 9 - 133 à 2 Pre-selection for all telescopic sections p. 9 - 133 à 3 Pre-selection for individual telescopic sections p.
Page 504 9 Operating elements for crane operation 9.4 Crane control operating elements Manual telescoping menu à 1 Locking status of telescopic section display p. 9 - 135 à 2 Lock/release telescopic section symbol p. 9 - 135 à 3 Telescoping cylinder in telescopic section display p.
Page 505: Active Working Range Limiter Menu Group
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.8 Active working range limiter menu group à 1 Overall height menu p. 9 - 64 à 2 Working radius menu p. 9 - 65 à 3 Slewing angle menu p.
Page 506 9 Operating elements for crane operation 9.4 Crane control operating elements Overall height menu 1 Switch monitoring on/off 2 – Current overall height display – Accept limit value à 3 – Overall height limit value display p. 11 - 142 –...
Page 507 9 Operating elements for crane operation 9.4 Crane control operating elements Working radius menu 1 Switch monitoring on/off 2 Current working radius display 3 – Current working radius display à – Accept limit value p. 11 - 144 4 Working radius limit value display 5 –...
Page 508 9 Operating elements for crane operation 9.4 Crane control operating elements Slewing angle menu 1 Switch monitoring on/off 2 – Current slewing angle display – Accept limit value 3 – Slewing angle A limit value display – Manually enter limit value à...
Page 509 9 Operating elements for crane operation 9.4 Crane control operating elements Hoist rope travel limitation menu 1 Switch monitoring on-/off 2 Raise input confirmation 3 Lower input confirmation 4 Current hoist rope position display à p. 11 - 149 5 – Raise limit value display –...
Page 510: Information 1 Menu Group
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.9 Information 1 menu group à 1 Hydraulic pressure and fuel consumption menu p. 9 - 69 à 2 Datalogger menu (menu opens on the RCL display) p. 9 - 94 9 - 68 3 303 279 en Operating manual...
Page 511 9 Operating elements for crane operation 9.4 Crane control operating elements Hydraulic pressure and fuel consumption menu à 1 Angle gear temperature display p. 9 - 137 à 2 Slewing gear hydraulic circuit pressure display p. 9 - 137 à 3 Telescoping cylinder pressure display p.
Page 512: Engine/Additional Equipment Menu Group
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.10 Engine/Additional equipment menu group à 1 Economy menu p. 9 - 71 à 2 Remote control menu p. 9 - 72 à 3 Slewable spotlights menu p. 9 - 73 9 - 70 3 303 279 en Operating manual...
Page 513 9 Operating elements for crane operation 9.4 Crane control operating elements Economy menu à 1 Switching off Economy mode on/off p. 9 - 98 à 2 Setting time interval A p. 9 - 98 à 3 Setting time interval B p.
Page 514: Remote Control Menu
9 Operating elements for crane operation 9.4 Crane control operating elements Remote control menu à 1 Remote control menu p. 9 - 141 à 2 Remote control display p. 9 - 141 9 - 72 3 303 279 en Operating manual GMK5150XL...
Page 515 9 Operating elements for crane operation 9.4 Crane control operating elements Slewable spotlights menu à 1 Switch load tracking on/off p. 9 - 156 à 2 Increase the slewing speed p. 9 - 156 à 3 Reduce the slewing speed p.
Page 516: Telescoping Emergency Program Menu Group
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.11 Telescoping emergency program menu group à 1 Telescoping emergency program menu p. 9 - 75 à 2 Unknown telescoping menu p. 9 - 76 9 - 74 3 303 279 en Operating manual GMK5150XL...
Page 517 9 Operating elements for crane operation 9.4 Crane control operating elements Telescoping emergency program menu 1 Input of emergency program access code 2 Remaining time of emergency program display 3 Telescoping cylinder length displays 4 Position of telescoping cylinder in foot section display 5 –...
Page 518 9 Operating elements for crane operation 9.4 Crane control operating elements Unknown telescoping menu à 1 Input for telescopic section I p. 14 - 40 à 2 Input for telescopic section II p. 14 - 40 à 3 Input for telescopic section III p.
Page 519: Settings Menu Group
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.12 Settings menu group à 1 Crane cab menu p. 9 - 78 à 2 Set display brightness and date/time menu p. 9 - 79 à 3 Switch over units menu p.
Page 520 9 Operating elements for crane operation 9.4 Crane control operating elements Crane cab menu à 1 Windscreen interval duration selection/display p. 9 - 158 à 2 Skylight interval duration selection/display p. 9 - 158 à 3 Retract/extend step selection p. 12 - 178 à...
Page 521 9 Operating elements for crane operation 9.4 Crane control operating elements Set display brightness and date/time menu à 1 Set display brightness selection p. 5 - 17 à 2 Increase/reduce value p. 5 - 17 à 3 Display in percent p.
Page 522 9 Operating elements for crane operation 9.4 Crane control operating elements Switch over units menu 1 Display units in: – Metres – Degrees Celsius – Kilograms – Bar à p. 11 - 130 2 Display units in: – Feet – Degrees Fahrenheit –...
Page 523 9 Operating elements for crane operation 9.4 Crane control operating elements Control lever characteristic curve menu 1 Slewing gear characteristic curve 2 Telescoping mechanism characteristic curve 3 Derricking gear characteristic curve à 4 Main hoist characteristic curve p. 11 - 131 5 Auxiliary hoist characteristic curve 6 Lattice extension characteristic curve 7 Reset characteristic curve setting...
Page 524 9 Operating elements for crane operation 9.4 Crane control operating elements Power unit speeds menu 1 Enter slewing gear speed 2 Enter telescoping mechanism speed 3 Enter derricking gear speed à 4 Enter main hoist speed p. 11 - 127 5 Enter auxiliary hoist speed 6 Enter speed for derricking gear of lattice extension 7 Reset power unit speed setting...
Page 525: Information 2 Menu Group
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.13 Information 2 menu group à 1 Operating hours menu p. 9 - 84 à 2 Engine/transmission error menu p. 9 - 85 à 3 Crane operation error menu p.
Page 526 9 Operating elements for crane operation 9.4 Crane control operating elements Operating hours menu 1 Key code entry and confirmation 2 Slewing gear 3 Telescoping mechanism 4 Derricking gear 5 Main hoist 6 Transmission à 7 Engine p. 11 - 138 8 Locking system 9 Auxiliary hoist 10 Carrier...
Page 527 9 Operating elements for crane operation 9.4 Crane control operating elements Engine/ It is used in the same way as in the driver's cab. transmission error menu 1 Displaying errors / total errors 2 Engine symbol display 3 Transmission symbol display à...
Page 528 9 Operating elements for crane operation 9.4 Crane control operating elements Crane operation error menu 1 Displaying errors / total errors 2 Error message display à 3 Acknowledging errors p. 14 - 5 4 Previous error 5 Next error 9 - 86 3 303 279 en Operating manual GMK5150XL...
Page 529 9 Operating elements for crane operation 9.4 Crane control operating elements Program version menu à 1 Serial number display p. 14 - 3 à 2 Program version display (software package) p. 14 - 3 3 Information on current software Operating manual 3 303 279 en 9 - 87 GMK5150XL...
Page 530: Various Controls
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.14 Various controls à 1 Prewarming hydraulic oil p. 9 - 137 à 2 Operating the camera p. 12 - 176 à 3 Air traffic control light on/off p. 9 - 155 à...
Page 531: Query Menus
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.15 Query menus The query menus open automatically only. Control lever actuation query à p. 10 - 7 Outrigger span query à p. 11 - 42 Operating manual 3 303 279 en 9 - 89 GMK5150XL...
Page 532: Rcl Control Unit
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.16 RCL control unit 1 RCL display à 2 USB connection for data export p. 9 - 151 3 No function à 4 Switch off RCL buzzer p. 9 - 106 à...
Page 533: Menu-Independent Displays
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.17 Menu-independent displays à 1 Warning messages display p. 14 - 8 à 2 Working range limiter displays p. 11 - 140 à 3 RCL status display p. 11 - 51 Operating manual 3 303 279 en 9 - 91...
Page 534: Rcl Menus
9 Operating elements for crane operation 9.4 Crane control operating elements 9.4.18 RCL menus Monitoring menu 9 - 92 3 303 279 en Operating manual GMK5150XL...
Page 535 9 Operating elements for crane operation 9.4 Crane control operating elements à 1 RCL code display p. 11 - 45 à 1),2) 2 Current lattice extension inclination display p. 11 - 50 à 1),2) Angle of lattice extension display p. 11 - 46 à...
Page 536: Lifting Capacity
9 Operating elements for crane operation 9.4 Crane control operating elements Datalogger menu à 1 Export data p. 9 - 151 à 2 Display of export progress p. 9 - 151 à 3 USB connection for data export p. 9 - 151 à...
Page 537: Brief Description Of The Operating Elements
9 Operating elements for crane operation 9.5 Brief description of the operating elements Brief description of the operating elements Risk of accident by operating error! This section is not a complete operating manual. It only provides a general overview of the functionality of the operating elements. Before using the operating elements for the first time, read through the following chapters and the safety instructions listed there.
Page 538: General Rules For Buttons And Symbols On The Display
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.2 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 539: Engine
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.3 Engine à Side panel Starting the engine – from the crane cab, p. 10 - 4. Ignition lock – 0 Ignition off, engine off, key can be removed –...
Page 540 9 Operating elements for crane operation 9.5 Brief description of the operating elements Economy menu – Open: Select and confirm symbol (1) Select symbol and confirm for: 1 Switching off Economy mode on/off 2 Setting time interval A 3 Setting time interval B 4 Average consumption à...
Page 541: Adblue (Def) System
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.4 AdBlue (DEF) system CCS display Description of further symbols for warning and fault messages; à Warning messages on the CCS display, p. 8 - 23. AdBlue (DEF) warning 1 –...
Page 542: Exhaust Cleaning/Regeneration
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.5 Exhaust cleaning/regeneration Exhaust system menu – Open: Select and confirm symbol (1) Manually start exhaust system cleaning The engine is running. 1 – Select and confirm: –...
Page 543: Air Intake Inhibitor
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.6 Air intake inhibitor Air intake inhibitor menu – Open: Select and confirm symbol (1) Opening the air intake inhibitor The air intake inhibitor was automatically triggered. 1 –...
Page 544: Seat Contact Switch And Dead Man's Switch
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.7 Seat contact switch and dead man's switch The seat contact switch and the dead man's switch are safety devices for enabling crane functions. Enabling crane functions –...
Page 545: Ccs Crane Control
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.8 CCS crane control The GMK5150XL 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 546 9 Operating elements for crane operation 9.5 Brief description of the operating elements In the Menu area – For selecting and opening menus. One symbol is always selected. Selecting a menu 1 Slew 2 Press – The next symbol is highlighted. Open the menu 1 Press 3 Press...
Page 547 9 Operating elements for crane operation 9.5 Brief description of the operating elements In the Operation area – For carrying out movements during rigging. The required element is marked, e.g. supporting cylinder (1). – For switching on/off and switching over A symbol for a status is highlighted, e.g.
Page 548 9 Operating elements for crane operation 9.5 Brief description of the operating elements Exit menu/input mode 1 Press: – The open menu closes – the menu from the next higher level is opened – Input mode is disabled. Overview of menu groups 1 Press: –...
Page 549 9 Operating elements for crane operation 9.5 Brief description of the operating elements Display temperature warning display The temperature of the control unit is measured by an internal sensor. – Blue, flashing: Temperature too low – display is not switched on Temperature too high: –...
Page 550 9 Operating elements for crane operation 9.5 Brief description of the operating elements Serial number and program version display 1 Truck crane serial number 2 Current program version of the crane control – always state in the event of a malfunction; à...
Page 551: Outrigger - Crane Cab
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.9 Outrigger – crane cab à Extending/retracting outrigger beams, p. 12 - 43 à Extending/retracting supporting cylinders, p. 12 - 51 The display fields must be switched on for crane operation – in the driver's cab, in the Settings menu on the CCS display.
Page 552 9 Operating elements for crane operation 9.5 Brief description of the operating elements Parking brake/movements disabled display/warning – Red: Parking brake released – outrigger movements disabled – Gone out: Parking brake applied – outrigger movements enabled à p. 12 - 36 Outrigger lighting on/off –...
Page 553 9 Operating elements for crane operation 9.5 Brief description of the operating elements Switch over/exit the menu Select symbol and confirm – symbol is green 1 Exit menu: 2 Outrigger beam menu 3 Outrigger cylinders menu Outrigger pre-selection The corresponding supporting cylinder or outrigger beam is pre-selected, depending on the menu that is open.
Page 554: Outrigger Control Units
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.10 Outrigger control units à Extending/retracting outrigger beams, p. 12 - 43 à Extending/retracting supporting cylinders, p. 12 - 51 à All directional information refers to the carrier; p.
Page 555 9 Operating elements for crane operation 9.5 Brief description of the operating elements Outrigger menu The operating elements for the outriggers are only active when the Outrigger menu is open. Outrigger menu – Open: Press button (2) repeatedly until display (1) appears. Outrigger span display 1 Individual width –...
Page 556 9 Operating elements for crane operation 9.5 Brief description of the operating elements Operating the left outrigger (next to control unit) Button (5) or (6) is pressed. 1 Retract: Press button – outrigger beam retracts 2 Extend: Press button – outrigger beam extends 3 Retract: Press button –...
Page 557: Raise Axle
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.11 Raise axle à Operating the axle raising system, p. 12 - 60 Raise axle menu The suspension is switched off (locked). – Open: Press button (2) repeatedly until display (1) appears. The operating elements for raising the axles are only active when the Raise axle menu is open.
Page 558 9 Operating elements for crane operation 9.5 Brief description of the operating elements Raising/lowering wheels The axle load on the pre-selected wheels is 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 559: Inclination Indicators
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.12 Inclination indicators à Inclination indicators, p. 12 - 54 Current inclination display A In the Monitoring menu B In the Outrigger menu C At the Outrigger control units 1 Measuring range display 2 Inclination indicator 3 Directional indicator...
Page 560: Outrigger Pressure Displays
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.13 Outrigger pressure displays Outrigger menu Outrigger pressure display – Unit of Displayed depending on setting measurement: – t – tons or – klbs – kilopounds – (1 kilopound = 1,000 lbs) –...
Page 561: Counterweight Menu
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.15 Counterweight menu à Rigging/unrigging the counterweight, p. 12 - 65, à Counterweight hoist unit, p. 12 - 104. – Open: Select and confirm symbol (1) Rigging position display 1 White –...
Page 562 9 Operating elements for crane operation 9.5 Brief description of the operating elements Rigging automatic mode – 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 563 9 Operating elements for crane operation 9.5 Brief 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 564 9 Operating elements for crane operation 9.5 Brief description of the operating elements Slewing enabled display 1 Green: Slewing enabled (if no other shutdown 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 565: Main Hoist
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.16 Main hoist Control panels Main hoist on/off – Press once: – Lamp bright – main hoist on – Lamp dim – main hoist off à p. 11 - 78 Right control lever –...
Page 566 9 Operating elements for crane operation 9.5 Brief description of the operating elements High-speed mode monitoring for hoist – Lights up: High-speed mode on – Gone out: High-speed mode off à p. 11 - 115 Lift/lower hoist display – Symbol (1): Lift –...
Page 567: Auxiliary Hoist
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.17 Auxiliary hoist Control panels Auxiliary hoist on/off – Press once: – Lamp bright – auxiliary hoist on – Lamp dim – auxiliary hoist off à p. 11 - 81 Left control lever –...
Page 568 9 Operating elements for crane operation 9.5 Brief description of the operating elements CCS display Power units display – Green: Auxiliary hoist on – Orange: Auxiliary hoist off High-speed mode monitoring for hoists – Lights up: High-speed mode on – Gone out: High-speed mode off à...
Page 569: Slewing Gear
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.18 Slewing gear à Slewing gear, p. 11 - 117. Control panels Slewing gear on/off – Press once: – Lamp bright – slewing gear on Slewing gear brake released –...
Page 570 9 Operating elements for crane operation 9.5 Brief description of the operating elements CCS display Power units display – Green: Slewing gear on – Orange: Slewing gear off Slewing gear brake applied/released 1 Lights up: Slewing gear brake applied 1 Gone out: Slewing gear brake released à...
Page 571: Derricking Gear
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.19 Derricking gear à Derricking gear, p. 11 - 87. Control panels Derricking gear on/off – Press once: – Lamp bright – derricking gear on, Power units with the same control lever configuration off –...
Page 572 9 Operating elements for crane operation 9.5 Brief description of the operating elements CCS display Power units display – Green: Derricking gear on – Orange: Derricking gear off Derricking gear high-speed mode monitoring – Lights up: High-speed mode on – Gone out: High-speed mode off à...
Page 573: Telescoping Mechanism
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.20 Telescoping mechanism à Control panels Telescoping mechanism, p. 11 - 91. Telescoping mechanism on/off – Press once: – Lamp bright – telescoping mechanism on, Power units with the same control lever configuration off –...
Page 574 9 Operating elements for crane operation 9.5 Brief description of the operating elements CCS display Telescoping mechanism high-speed mode monitoring – Lights up: High-speed mode on – Gone out: High-speed mode off à p. 11 - 115 Power units display –...
Page 575 9 Operating elements for crane operation 9.5 Brief description of the operating elements Telescoping cylinder length display – Display: Current extended length of the telescoping cylinder – Unit of Displayed in percent (%) and, depending on setting, measurement: mm (millimetres) or ft (feet) à...
Page 576 9 Operating elements for crane operation 9.5 Brief description of the operating elements Pre-selection for individual telescopic sections 1 - 6 Display of telescopic sections 1 to 6 Confirming pre-selection 1 Confirm pre-selected telescoping 2 Telescoping permitted display 3 Telescoping not permitted display à...
Page 577 9 Operating elements for crane operation 9.5 Brief description of the operating elements Locking point display 1 Extend telescoping cylinder 2 Retract telescoping cylinder Lock/unlock telescoping cylinder – To lock: – Telescopic section is locked: Select symbol (2) and confirm – telescoping cylinder is locked –...
Page 578 9 Operating elements for crane operation 9.5 Brief description of the operating elements Main boom length display – Display: Current extended length of the main boom – Unit of Displayed depending on setting, in mm (millimetres) or measurement: ft (feet) à...
Page 579: Hydraulic System
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.21 Hydraulic system Inclining the crane cab – Press at bottom: Incline to the rear – Press at top: Incline to the front à p. 11 - 125 Hydraulic pressure and fuel consumption menu –...
Page 580: Superstructure Lock/Houselock Menu
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.22 Superstructure lock/houselock menu – Open: Select and confirm symbol (1) à Superstructure Locking/unlocking the superstructure, p. 11 - 15. lock Locking status display The current position of the locking pin is shown by different symbols: 1 and 7 Red –...
Page 581 9 Operating elements for crane operation 9.5 Brief description of the operating elements Current slewing angle display 0°: Position 0° to the rear – locking point 180°: Position 180° to the front – locking point +0.1 to +180.0°: Turned clockwise from 0° -0.1 to -179.9°: Turned anti-clockwise from 0°...
Page 582 9 Operating elements for crane operation 9.5 Brief description of the operating elements à Houselock Switching the houselock on/off, p. 11 - 17. Locking status display 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 583: Remote Control
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.23 Remote control Operation with the remote control is only enabled for the Standard slewing range type. Remote control menu – Open: Select and confirm symbol (1) Remote control display 1 –...
Page 584: Rated Capacity Limiter (Rcl)
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.24 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 Limited slewing range, e.g.
Page 585: Current Position Display
9 Operating elements for crane operation 9.5 Brief description of the operating elements Maximum permissible working radius display Shows the maximum permissible working radius (5) for each slewing range. 1 Display area – always corresponds to the largest maximum working radius (5) 2 Maximum permissible working radius in the corresponding slewing range with the currently lifted load...
Page 586 9 Operating elements for crane operation 9.5 Brief description of the operating elements Maximum permissible speed display Separate displays are provided for each direction of movement. 1 Slew anti-clockwise 2 Slew clockwise 3 Lower main hoist 4 Lift main hoist 5 Lower auxiliary hoist 6 Lift auxiliary hoist 7 Lower...
Page 587 9 Operating elements for crane operation 9.5 Brief description of the operating elements In the Enter rigging mode/telescope status menu – Open: Select and confirm symbol (1) – Opens automatically after ignition on. Enter slewing range In input mode Select slewing range symbol and confirm –...
Page 588 9 Operating elements for crane operation 9.5 Brief description of the operating elements Reeving input mode display 1 Main hoist 2 Auxiliary hoist Orange: Grey: à Entering the rigging mode, p. 11 - 32 Enter reeving 1 Main hoist In input mode – select and confirm current reeving 2 Auxiliary hoist –...
Page 589 9 Operating elements for crane operation 9.5 Brief description of the operating elements Boom system display A Main boom display B Lattice extension display C Heavy load lattice extension display 1 Lattice extension angle display (for inclinable lattice extension) Enter boom system For the Standard slewing range type only.
Page 590 9 Operating elements for crane operation 9.5 Brief description of the operating elements Accept the measured outrigger span Select and confirm – the outrigger span provided by outrigger span monitoring is à applied and shown on the Enter outrigger span display; Confirming the rigging mode and lifting capacity table, p.
Page 591 9 Operating elements for crane operation 9.5 Brief description of the operating elements Outrigger span monitoring display (standard) Query after confirming the rigging mode. A Measured outrigger span = required outrigger span B Measured outrigger span ≠ required outrigger span (query menu) 2 Required outrigger span –...
Page 592 9 Operating elements for crane operation 9.5 Brief description of the operating elements In the Pre-selection of 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 593 9 Operating elements for crane operation 9.5 Brief description of the operating elements In the Datalogger menu à Datalogger, p. 11 - 68 – Open: Select and confirm symbol (1) à (Menu opens on the RCL display; RCL display, p. 9 - 151). RCL display In the Datalogger menu à...
Page 594 9 Operating elements for crane operation 9.5 Brief description of the operating elements RCL override – This version only applies to RCL programming according to EN 13000. à version A For other RCL programming; p. 9 - 153. RCL override Press once: RCL shutdown overridden –...
Page 595 9 Operating elements for crane operation 9.5 Brief description of the operating elements RCL override – This version only applies to RCL programming deviating from EN 13000. For RCL à version B programming according to EN 13000; p. 9 - 152. Overriding the RCL in an emergency –...
Page 596: Electrical System
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.25 Electrical system 12 V sockets 1 12 V/max. 15 A 2 24 V/max. 15 A 3 Cigarette lighter 24 V/max. 15 A Only connect electrical devices with the matching specification to the socket.
Page 597: Lighting, Windscreen Wiper/Washing System
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.26 Lighting, windscreen wiper/washing system Lighting Air traffic control light on/off – Switch on: Select symbol (2) and confirm – symbol (1) is displayed – Switch off: Select symbol (1) and confirm –...
Page 598 9 Operating elements for crane operation 9.5 Brief description of the operating elements Spotlight II on/off Spotlight at the rear on the turntable Switching on also possible with the ignition switched off. – Switch on: Press at the bottom – lamp in the button on –...
Page 599 9 Operating elements for crane operation 9.5 Brief description of the operating elements Cab lighting 1 Switch on continuously 2 Switch off continuously 3 On/off via door contact Reading lamp 1 Switching on 2 Switching off Windscreen wiper/ washing system Windscreen wiper on/off –...
Page 600 9 Operating elements for crane operation 9.5 Brief description of the operating elements Crane cab menu – Open: Select and confirm symbol (1) Adjusting the wiping interval 1 Windscreen wiper selection, (5) displayed 2 Roof window wiper selection, (6) displayed 7 Chang interval duration Wiper interval in seconds for 3 Windscreen wiper...
Page 601: Hand-Held Control
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.27 Hand-held control à Engine control Starting the engine – with the hand-held control, p. 10 - 12 panel 1 Voltage monitoring – Lights up: Ignition on –...
Page 602 9 Operating elements for crane operation 9.5 Brief description of the operating elements à Emergency Emergency operation with the hand-held control, p. 14 - 42 operation Pre-select emergency operation 1 Main hoist 2 Telescoping mechanism 3 Lattice extension derricking gear 4 Auxiliary hoist 5 Derricking gear 6 Slewing gear...
Page 603: Windows And Doors
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.28 Windows and doors Windows The handles on the windscreen and the rear window have the same function. (A) – Open window • Turn both handles (1) inwards. •...
Page 604 9 Operating elements for crane operation 9.5 Brief description of the operating elements Crane cab door From outside Unlock • Turn the key in direction A. Lock • Turn the key in direction B. Open/close • Pull the handle (1). •...
Page 605: Diagnostics
9 Operating elements for crane operation 9.5 Brief description of the operating elements 9.5.29 Diagnostics The diagnostic connections may only be operated by the service personnel. The diagnostic connections (1) are behind the cover (2). Additional diagnostic and service connections are provided on the CCS and RCL control units (3).
Page 606 9 Operating elements for crane operation 9.5 Brief description of the operating elements Blank page 9 - 164 3 303 279 en Operating manual GMK5150XL...
Page 607: Short Description Of The Operating Elements - Driving From The Crane Cab
9 Operating elements for crane operation 9.6 Short description of the operating elements – driving from the crane cab Short description of the operating elements – driving from the crane cab 9.6.1 Driving menu Driving menu – Open: Select symbol (1) and confirm – menu is opened The menu is also opened the first time the parking brake is à...
Page 608 9 Operating elements for crane operation 9.6 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 609: Transmission
9 Operating elements for crane operation 9.6 Short description of the operating elements – driving from the crane cab 9.6.2 Transmission Operating the transmission when driving with rigged truck crane; à Operating the transmission, p. 13 - 31. The following applies to all operating elements: –...
Page 610: Switch Off
9 Operating elements for crane operation 9.6 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 does not shift –...
Page 611: Final Drive
9 Operating elements for crane operation 9.6 Short description of the operating elements – driving from the crane cab 9.6.3 Final drive Driving menu – Open: Select and confirm symbol (1) Transverse differential locks on/off – Switch on: Select symbol (1) and confirm – symbol is red –...
Page 612: Brakes
9 Operating elements for crane operation 9.6 Short description of the operating elements – driving from the crane cab 9.6.4 Brakes Service brake The pedal (1) acts on the carrier brakes – for continuously variable adjustment of the braking force. CCS display Driving menu –...
Page 613: Steering
9 Operating elements for crane operation 9.6 Short description of the operating elements – driving from the crane cab Applying/releasing the parking brake – Apply: – Press once at the bottom – the lamp lights up, Parking brake applied à After driving, p.
Page 614 9 Operating elements for crane operation 9.6 Short description of the operating elements – driving from the crane cab CCS display Changing the steering direction Steering direction display 1 Steering wheel steering direction 2 Reverse steering direction (compared to steering wheel) Switch over: –...
Page 615 9 Operating elements for crane operation 9.6 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 616 9 Operating elements for crane operation 9.6 Short description of the operating elements – driving from the crane cab Steering malfunction (1) symbol displayed and symbol (2) yellow. – Displayed only briefly and goes out again Continued driving possible, error was saved –...
Page 617 9 Operating elements for crane operation 9.6 Short description of the operating elements – driving from the crane cab Control panels The information in this section is based on the set Steering wheel steering direction. Steering with separate steering – manual The symbol (3) is displayed.
Page 618 9 Operating elements for crane operation 9.6 Short description of the operating elements – driving from the crane cab Blank page 9 - 176 3 303 279 en Operating manual GMK5150XL...
Page 619: 10 Starting/Switching Off The Engine - For Crane Operation
10 Starting/switching off the engine – for crane operation Starting/switching off the engine – for crane operation This chapter describes how to start the engine / switch it off from within the crane cab and using the hand-held control. For starting the engine / switching it off from within the driver's cab and at the à...
Page 620 10 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 driver’s cab, then you must shut it down in the driver’s cab and switch off the ignition before crane operation.
Page 621: When Starting The Engine For The First Time In The Day
10 Starting/switching off the engine – for crane operation 10.1 When starting the engine for the first time in the day 10.1 When starting the engine for the first time in the day Risk of crushing due to turning wheels! When you start the engine, no persons may be within the steering range of the 3rd to 5th axle lines.
Page 622: Starting The Engine - From The Crane Cab
10 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 Checking the fuel level and AdBlue (DEF) level • Check the fuel level, and the AdBlue (DEF) level if necessary, before starting the engine.
Page 623: Checks Before Starting The Engine
10 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 624: Switching On The Ignition
10 Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.3 Switching on the ignition Do not start the engine until the CCS display shows a menu (usually the Enter rigging mode menu). The control levers must be in their initial positions.
Page 625: Control Lever Actuation Query
10 Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.4 Control lever actuation query When the ignition is switched on, a query appears asking if both control levers (2) are in their initial positions.
Page 626: Synchronisation Of The Switching States
10 Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.5 Synchronisation of the switching states When the ignition is switched on, various switching operations are performed automatically and the switching states of the differential locks and the steering are synchronised.
Page 627: Display - Adjusting The Brightness
10 Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.6 Display – Adjusting the brightness • Open the menu (1) – Set display brightness and date/time menu. à It is used in the same way as in the driver's cab; p.
Page 628: Checks After Starting The Engine
10 Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.8 Checks after starting the engine • Check the display (1) at the CCS control unit immediately after starting the engine. When a symbol is displayed in the display à...
Page 629: Setting The Idling Speed
10 Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.9 Setting the idling speed à • Start the engine; p. 10 - 9. • Open the start menu – button (1). The display (2) shows the current engine speed You can increase the idling speed for crane operation.
Page 630: Starting The Engine - With The Hand-Held Control
10 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 Starting with the hand-held control is only intended for emergency operation and permits derricking of the lattice extension during rigging. à...
Page 631: With The Hand-Held Control
10 Starting/switching off the engine – for crane operation 10.4 Switching off the engine 10.4.2 With the hand-held control à Switching off the engine, p. 14 - 48 10.4.3 After switching off Refer to the instructions in the respective sections for each type of work interruption;...
Page 632: Using The Emergency Stop Switches
10 Starting/switching off the engine – for crane operation 10.4 Switching off the engine 10.4.4 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 633: Crane Operation
11 Crane operation 11.1 Before operating the crane Crane operation 11.1 Before operating the crane 11.1.1 CHECKLIST: Checks before crane 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 there. This checklist only applies to work with a rigged truck crane (supported and rigged with counterweight).
Page 634 11 Crane operation 11.1 Before operating the crane 3. Switch on cameras as required. à Cameras on the hoists, p. 12 - 173 à Camera on the main boom, p. 12 - 173 à Camera on the driver's cab, p. 12 - 175 4.
Page 635 11 Crane operation 11.1 Before operating the crane à 8. Start the engine for crane operation; p. 10 - 9 9. Check – RCL, – lifting limit switch, – seat contact switch and dead man's switch, – emergency stop switch, à...
Page 636 11 Crane operation 11.1 Before operating the crane 14. For others the operating positions – Unlock the turntable – provided the systems are present à Unlocking the superstructure, p. 11 - 16 à Switching off the houselock, p. 11 - 19 à...
Page 637: Checking The Condition Of The Truck Crane
11 Crane operation 11.1 Before operating the crane 11.1.2 Checking the condition of the truck crane Crane cab heater Use the same fuel as for the engine or use EL heating oil for refuelling. fuel tank Danger of fire due to flammable gases! Switch off the engine and heating system before refuelling.
Page 638 11 Crane operation 11.1 Before operating the crane Checking the position of the hoist ropes Risk of crushing due to turning rope drum! Keep away from the rope drum while it is turning. This will prevent your limbs from being drawn in or crushed. •...
Page 639 11 Crane operation 11.1 Before operating the crane • Checking the Check the listed functions and have faulty parts repaired. electrical system – Windscreen/skylight: Windscreen wipers, windscreen washing system – Spotlights I, II and III, outrigger lighting – Slewable spotlights, –...
Page 640: Adjusting The Crane Cab Seat And Control Panels
11 Crane operation 11.1 Before operating the crane 11.1.3 Adjusting the crane cab seat and control panels Crane cab seat You can adjust the crane cab seat to your height. Version 1 1 Back rest – angle 2 Seat – height 3 Seat –...
Page 641: Adjusting The Front Panel
11 Crane operation 11.1 Before operating the crane Control panels You can adjust the height of the front control panels. 1 Storage compartment with lid 2 Control panel, left – height 3 Drawer 4 Control panel, right – height 5 USB charging connection (5 V / 2 x 2.5 A) 11.1.4 Adjusting the front panel You can adjust the height and inclination.
Page 642: Checking The Safety Devices
11 Crane operation 11.1 Before operating the crane 11.1.5 Checking the safety devices Risk of accidents when working with faulty safety devices! 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 Grove Product Support •...
Page 643 11 Crane operation 11.1 Before operating the crane • Emergency stop Set down the load and let go of both control levers. switch • Press the emergency stop switch (3) so that it engages. • Check whether the engine stops. •...
Page 644 11 Crane operation 11.1 Before operating the crane Seat contact This check is carried out together with the dead man's switch. switch Danger of accidents if the seat contact switch is faulty! Always perform this check inside the crane cab. If you stand next to the crane cab, you may be pushed off the carrier if the superstructure slews as a result of a faulty dead man's switch.
Page 645: Earthing The Load
11 Crane operation 11.1 Before operating the crane 11.1.6 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 sheaves made of synthetic material or non-conducting sling gear is used.
Page 646: Prewarming Hydraulic Oil
11 Crane operation 11.1 Before operating the crane 11.1.7 Prewarming 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 647: Locking/Unlocking The Superstructure
11 Crane operation 11.1 Before operating the crane 11.1.8 Locking/unlocking the superstructure In the case of equipment with superstructure 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°. •...
Page 648 11 Crane operation 11.1 Before operating the crane Locking the The superstructure needs to be at one of the locking points (0° or 180°). superstructure • Select the symbol (5). • Press the button until the symbol (4) is displayed – Superstructure locked. The display changes from symbol (1) to symbol (2) and shows symbol (6) when the superstructure is locked.
Page 649: Switching The Houselock On/Off
11 Crane operation 11.1 Before operating the crane 11.1.9 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 locks the slewing gear. Switching on the Slew the superstructure to the position in which it is to be locked and then stop houselock...
Page 650 11 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 651 11 Crane operation 11.1 Before operating the crane • Switching off the Check that the slewing gear is switched off, and switch if off if necessary; à houselock Switching off the slewing gear, p. 11 - 17. Risk of damage during slewing! Always switch off the slewing gear before you operate the houselock.
Page 652: Setting The Time
11 Crane operation 11.1 Before operating the crane 11.1.10 Setting the time • Open the menu (1) – Crane cab menu. • Select and confirm the symbol (1). Setting the time • Select and confirm the symbol (2). • Select the current time – as a deviation from UTC time.
Page 653: Standard Slewing Range Type
11 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 equipment; à MAXbase slewing range type, p. 11 - 23. The Standard slewing range type is always available. The lifting capacity tables with symmetrical outrigger spans apply.
Page 654 11 Crane operation 11.2 Standard slewing range type 180° to the front The same lifting capacity tables apply to this position as to the 360° slewing rigging position range. • Free-on-wheels Check that the truck crane has been rigged for free on wheels operation; à...
Page 655: Maxbase Slewing Range Type
11 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 range type; à Permissible slewing ranges and operating positions, p. 11 - 21. You must decide between the two slewing range types when entering the rigging mode.
Page 656: Information In The Lifting Capacity Tables
11 Crane operation 11.3 MAXbase slewing range type 11.3.1 Information in the lifting capacity tables The specified lifting capacities are only enabled for specific slewing ranges. The Lifting capacity table contains directional information for the enabled slewing range, which is assigned to a superstructure position. Directional Superstructure information...
Page 657 11 Crane operation 11.3 MAXbase slewing range type 11.3.2 Enabled slewing ranges The enabled angular ranges around the starting point are given 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 an outrigger span of 7.600 m (25.0 ft).
Page 658 11 Crane operation 11.3 MAXbase slewing range type Smallest individual width 2.950 m (9.7 ft) This case applies if one or more outrigger beams are extended to an outrigger span of 2.950 m (9.7 ft) and all other outrigger beams are extended to larger spans.
Page 659: Enabled Slewing Ranges
11 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 an outrigger span of 1.250 m (4.1 ft) and all other outrigger beams are extended to larger spans. Directional information Angular range Enabled slewing range...
Page 660: Lifting Capacities And Slewing Ranges For Outrigger Spans Without Separate Lifting Capacity
11 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 opposite 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 661: Operating The Rated Capacity Limiter
11 Crane operation 11.4 Operating the rated capacity limiter 11.4 Operating the rated capacity limiter The rated capacity limiter is abbreviated as RCL (Rated-Capacity-Limiter) in this operating manual. If the truck crane's current rigging mode is entered correctly, the RCL will prevent the permissible lifting capacity being exceeded and the truck crane being overloaded.
Page 662: Switching On The Rcl
11 Crane operation 11.4 Operating the rated capacity limiter 11.4.1 Switching on the RCL Switching on The RCL is switched on together with the ignition. • Switch on the ignition. A test program runs after switching on the ignition. • Check whether you can hear a buzzer tone.
Page 663 11 Crane operation 11.4 Operating the rated capacity limiter Temperature on the display The brightness is reduced automatically if the temperature on a display is too high.If the temperature on the display exceeds around 60 °C (140 °F), then the à...
Page 664: Entering The Rigging Mode
11 Crane operation 11.4 Operating the rated capacity limiter 11.4.2 Entering the rigging mode Notes on input You can enter the rigging mode for various different purposes. – Input 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 665 11 Crane operation 11.4 Operating the rated capacity limiter Entering the Possible types are the Standard slewing range type and, with the corresponding slewing range equipment, the MAXbase slewing range type. type Different lifting capacity tables apply depending on the entered slewing range type and these then impact further input of the rigging mode.
Page 666 11 Crane operation 11.4 Operating 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 Operating position 0° to the rear 4 Limited slewing range 5 Operating position –...
Page 667 11 Crane operation 11.4 Operating 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 limited if you adhere to this sequence when entering the data. 1 Slewing range –...
Page 668 11 Crane operation 11.4 Operating the rated capacity limiter Outrigger span You can apply the outrigger span provided by outrigger span monitoring or manually enter the outrigger span. Applying the outrigger span • Select and confirm the symbol (2). The outrigger span provided by outrigger span monitoring is applied and shown on the current display (1).
Page 669 11 Crane operation 11.4 Operating the rated capacity limiter Entering the outrigger span (MAXbase) The outrigger spans are entered as individual widths. If the Lifting capacity table specifies an overall width then select the corresponding individual width. Overall width Individual width 7.600 m (25.0 ft) 3.800 m (12.5 ft) 6.700 m (22.0 ft)
Page 670 11 Crane operation 11.4 Operating the rated capacity limiter Counterweight • Select and confirm the display (1). • Select the rigged counterweight combination, for example, 16.5 t. • Confirm the selection. The display (2) shows the entered counterweight combination. Boom system For the Standard slewing range type only.
Page 671 11 Crane operation 11.4 Operating the rated capacity limiter The confirmed boom system (1) or (2) is displayed. Reeving • (A) – Select and confirm the display for the hoist to be used for lifting the load, e.g. display (1) for the main hoist – symbol (3) is orange.
Page 672: Pre-Selecting Telescoping
11 Crane operation 11.4 Operating the rated capacity limiter Entering the RCL You must enter the RCL code for the rigging mode according to the code Lifting capacity table. • Refer to the Lifting capacity table for the current rigging mode. The corresponding RCL code (1) is given at the bottom of the table (e.g.
Page 673: Confirming The Rigging Mode And Lifting Capacity Table
11 Crane operation 11.4 Operating the rated capacity limiter 11.4.4 Confirming the rigging mode and lifting capacity table You must confirm the rigging mode together with the displayed lifting capacity table before starting crane operation. Some parts of the procedure are different, depending on the slewing range type entered.
Page 674 11 Crane operation 11.4 Operating the rated capacity limiter • Select and confirm the symbol (1). If the rigging mode is permitted The rigging mode is applied together with the displayed lifting capacity table. The RCL display shows the Monitoring menu. The CCS display shows the Start menu.
Page 675 11 Crane operation 11.4 Operating the rated capacity limiter Risk of accidents due to incorrectly supported truck crane! A shutdown is not carried out in the standard case when an outrigger span mon- itoring 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 676 11 Crane operation 11.4 Operating the rated capacity limiter • Select and confirm the symbol (1). If the rigging mode is permitted The rigging mode is applied together with the displayed lifting capacity table. The RCL display shows the Monitoring menu. The CCS display shows the Start menu.
Page 677: Checks Before Crane Operation
11 Crane operation 11.4 Operating the rated capacity limiter 11.4.5 Checks before crane operation 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 operation on the CCS display.
Page 678 11 Crane operation 11.4 Operating 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 connected to the power supply.
Page 679 11 Crane operation 11.4 Operating the rated capacity limiter Hoist check 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 want to lift the load.
Page 680 11 Crane operation 11.4 Operating the rated capacity limiter Blank page 11 - 48 3 303 279 en Operating manual GMK5150XL...
Page 681: Displays During Crane Operation
11 Crane operation 11.4 Operating the rated capacity limiter 11.4.6 Displays during crane operation Various different information is shown on the RCL display and CCS display. This section only describes the displays that change during crane operation. On the RCL All displays are shown in the Monitoring menu.
Page 682 11 Crane operation 11.4 Operating the rated capacity limiter Current main boom angle display 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 683 11 Crane operation 11.4 Operating 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 684 11 Crane operation 11.4 Operating the rated capacity limiter Telescoping cylinder position display The bar (1) 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 which telescoping direction.
Page 685 11 Crane operation 11.4 Operating the rated capacity limiter On the CCS After confirming a permissible rigging mode, the Start menu opens automatically. display Standard slewing range type à If the MAXbase slewing range type was entered; p. 11 - 55. The RCL display differs according to the confirmed slewing range.
Page 686: Operating Position
11 Crane operation 11.4 Operating the rated capacity limiter Limited slewing range The diagram (1) shows the released slewing range and the slewing range limits (3), for example, +30° and -30°. – When telescoping or derricking The diagram (1) remains at the current position. The displays (2) move up or down.
Page 687 11 Crane operation 11.4 Operating the rated capacity limiter MAXbase slewing range type à If the Standard slewing range type was entered; p. 11 - 53. Display of the slewing ranges The RCL display shows the four enabled slewing ranges in a diagram with four ranges.
Page 688 11 Crane operation 11.4 Operating 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 the slewing range – When telescoping or derricking The diagram remains at the current position. The displays (2) move a corresponding distance up or down.
Page 689: Rcl Early Warning
11 Crane operation 11.4 Operating 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 sounds. After five seconds, you can switch off the buzzer tone using button (3) or (4).
Page 690 11 Crane operation 11.4 Operating the rated capacity limiter – All crane movements that increase the load moment are switched off. – A continuous buzzer tone sounds. After five seconds, you can switch off the buzzer tone using button (6) or (7). –...
Page 691: Displaying The Lifting Capacity Tables
11 Crane operation 11.4 Operating the rated capacity limiter 11.4.9 Displaying the lifting capacity tables • Open the menu (1) – Lifting capacity tables menu. Exit menu • Press the button (1) or press the button (2) on the CCS control unit once – the start menu opens.
Page 692 11 Crane operation 11.4 Operating 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 auxiliary hoist, for example, maximum load 18 t Slewing range display...
Page 693 11 Crane operation 11.4 Operating the rated capacity limiter à MAXbase slewing If the Standard slewing range type was entered; p. 11 - 59. range type Permissible working range display The displays apply to the confirmed rigging mode. 1 Slewing range display – four slewing ranges, marked in colour 2 Permissible working range display –...
Page 694 11 Crane operation 11.4 Operating the rated capacity limiter Slewing range display The display is same in all four slewing ranges. 1 Coloured: Released sslewing 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 695 11 Crane operation 11.4 Operating the rated capacity limiter 11.4.10 RCL override – version A This section applies only when the supplied Lifting capacity tables contain the entry EN 13000 in the header (1). à In the case of other entries; RCL override –...
Page 696 11 Crane operation 11.4 Operating the rated capacity limiter When rigging For rigging work, you can: à – override the lifting limit switch; p. 11 - 85 – 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 697 11 Crane operation 11.4 Operating 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 is above 100% and the crane movements are switched off.
Page 698 11 Crane operation 11.4 Operating the rated capacity limiter In emergencies With this type of override, the complete shutdown of the RCL is cancelled and no monitoring takes place. Risk of accidents due to overridden or faulty RCL! It is not permitted to work with an overridden or faulty RCL! Set down the load immediately and stop operating the crane if the RCL is faulty! You may only override the RCL if it becomes absolutely necessary in an emer- gency.
Page 699: Rcl Override - Version A
11 Crane operation 11.4 Operating the rated capacity limiter 11.4.11 RCL override – version B This section only applies when the supplied Lifting capacity tables contain an entry other than EN 13000 in the header (1), e.g. the entry ASME. à...
Page 700: Datalogger
11 Crane operation 11.4 Operating the rated capacity limiter 11.4.12 Datalogger You can export data from the CCS crane control system to a USB stick and display it on a PC using the CraneEvaluation program supplied. • Open the menu (1) – Datalogger menu. (menu opens on the RCL display).
Page 701 11 Crane operation 11.4 Operating the rated capacity limiter Displaying You need the CraneEvaluation program in order to display the exported data. The the data installation program is located in the CraneEvaluation folder on the owner's USB stick supplied. Importing data •...
Page 702 11 Crane operation 11.4 Operating 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 lifting operations per day 4 Number of lifting operations per reeving 5 Number of lifting operations per utilisation area...
Page 703 11 Crane operation 11.4 Operating the rated capacity limiter Displaying tables • Select the symbol (1) – a table is opened. 2 List with all lifting operations 3 List with all events 4 List with all actuated switches If the Crane use graphic is also open, an element is displayed and marked in the respective other window when clicked on.
Page 704 11 Crane operation 11.4 Operating the rated capacity limiter Blank page 11 - 72 3 303 279 en Operating manual GMK5150XL...
Page 705: Crane Operation With Main Boom
11 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 to alignment changing 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 706 11 Crane operation 11.5 Crane operation with main boom Checking the wind Strong winds can result in the truck crane becoming overloaded. 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 707 11 Crane operation 11.5 Crane operation with main boom Deformation of the One-sided direct sunlight can lead to a temperature difference between the left main boom due to and the right main boom side. This results in a different length extension. A lateral direct sunlight deformation of the main boom is the result.
Page 708 11 Crane operation 11.5 Crane operation with main boom Blank page 11 - 76 3 303 279 en Operating manual GMK5150XL...
Page 709: Main Hoist
11 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 on to the drum.
Page 710 11 Crane operation 11.5 Crane operation with main boom Switching on the After the ignition is switched on, all power units are switched off and the lamps in main hoist the corresponding buttons light up only dimly. • Check if the auxiliary hoist is switched off and therefore secured against unintentional operation.
Page 711 11 Crane operation 11.5 Crane operation with main boom Lifting and You can adjust the sensitivity of the control levers to the operating conditions; à lowering Setting the control lever characteristic curve, p. 11 - 131. Risk of accidents due to gaps in monitoring! Operation of the hoist is only fully monitored if: à...
Page 712 11 Crane operation 11.5 Crane operation with main boom Maximum The maximum permissible hoist rope speed is limited automatically depending on permissible hoist the degree of utilisation of the lifting capacity and reeving. The scale of the rope speed limitation is specified in the supplied lifting capacity table. à...
Page 713: Auxiliary Hoist
11 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 the safety instructions in the section Main hoist, p. 11 - 77 before operating the auxiliary hoist. All safety instructions for operating the main hoist also apply to the auxiliary hoist, along with the information in this section.
Page 714: Lifting And Lowering
11 Crane operation 11.5 Crane operation with main boom • Check that the current reeving of the auxiliary hoist is displayed, e.g. 6. à Correct the reeving if necessary; p. 11 - 39. Lifting and You can adjust the sensitivity of the control levers to the operating conditions; à...
Page 715 11 Crane operation 11.5 Crane operation with main boom You can set the desired engine speed (idling speed) with the button (1); à p. 10 - 11. Maximum The maximum permissible hoist rope speed is limited automatically depending on permissible hoist the degree of utilisation of the lifting capacity and reeving.
Page 716: Lifting Limit Switch And Lowering Limit Switch
11 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 - 158. The lifting limit switch (1) prevents the hook block being lifted up to the main boom head and damaging it.
Page 717 11 Crane operation 11.5 Crane operation with main boom Lifting limit switch override When overriding, shutdown of the lifting limit switch is cancelled and crane operation is no longer completely monitored. Risk of accidents if the lifting limit switch is overridden! You may only override the lifting limit switch if this is specified in the operating manual for carrying out maintenance or rigging work.
Page 718 11 Crane operation 11.5 Crane operation with main boom Lowering limit switch The lowering limit switch (1) prevents the hoist rope being reeled completely off the drum. The lowering limit switch works only if the switch-off point is set correctly à...
Page 719: Derricking Gear
11 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 switches off lowering of the boom as soon as the working area is left as specified in the Lifting capacity table.
Page 720: Raising And Lowering
11 Crane operation 11.5 Crane operation with main boom Raising and You can adjust the sensitivity of the control levers to the operating conditions; à lowering Setting the control lever characteristic curve, p. 11 - 131. Risk of accidents due to unexpected crane movements! If assigned more than one function, check that the Derricking control lever function is switched on before you move the control lever for derricking.
Page 721 11 Crane operation 11.5 Crane operation with main boom You can set the desired engine speed (idling speed) with the button (1); à p. 10 - 11. Maximum The maximum permissible derricking speed is limited automatically depending on derricking speed the system length.
Page 722: Horizontal Position
11 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 derricking gear unintentional use. • Press the button (1) once – the lamp lights up dimly. Symbol (2) is orange when the derricking gear is switched off.
Page 723: Telescoping Mechanism
11 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 processes at the right time.
Page 724 11 Crane operation 11.5 Crane operation with main boom Blank page 11 - 92 3 303 279 en Operating manual GMK5150XL...
Page 725 11 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) that are extended by spring force.
Page 726 11 Crane operation 11.5 Crane operation with main boom Telescoping This state should be the starting point for a telescoping process. A telescoping process process consists of 4 steps. 1. Unlocking the telescoping cylinder The locking pins (5) are retracted – the telescoping cylinder is unlocked.
Page 727 11 Crane operation 11.5 Crane operation with main boom 3. Unlocking the telescopic section (A) – The telescoping cylinder is extended until the locking pins (7) are clear. (B) – The mechanism (10) retracts the locking pins (7) – the telescopic section is unlocked. 4.
Page 728 11 Crane operation 11.5 Crane operation with main boom Assignment to The CCS display shows a sectional view of the main boom in the menus. 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 729 11 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, The lengths are automatically identified by the RCL, and the corresponding lifting telescoping length capacities according to the Lifting capacity table are enabled and displayed automatically.
Page 730 11 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 intermediate/ telescoping lengths in different ways.
Page 731 11 Crane operation 11.5 Crane operation with main boom Checks prior When the ignition is turned on, CCS determines the displayed telescoping status to starting from the current status of the telescoping mechanism and the previously saved operations locking and unlocking procedures. Normally, CCS detects deviations between the current and the displayed telescope status and displays a corresponding error message;...
Page 732 11 Crane operation 11.5 Crane operation with main boom Switching on the After the ignition is switched on, all power units are switched off and the lamps in telescoping the corresponding buttons light up only dimly. mechanism • Press the button (1) – the lamp lights up brightly. The symbol (2) is green when the telescoping mechanism is switched on.
Page 733 11 Crane operation 11.5 Crane operation with main boom The distance between the hook block and the boom head changes during telescoping. Make sure that the hook block does not trigger the lifting limit switch or touch the ground. • Additionally carry out the following movements –...
Page 734 11 Crane operation 11.5 Crane operation with main boom à You can switch on high-speed mode for a higher speed; p. 11 - 115. You can set the desired engine speed (idling speed) with the button (1); à p. 10 - 11. You can limit the maximum telescoping speed in the Power unit speeds menu;...
Page 735 11 Crane operation 11.5 Crane operation with main boom Manual To telescope manually, you must initiate all locking and unlocking processes. telescoping The locking and unlocking processes are carried out automatically. The following sections describe the operating procedures – Checking the initial position, à...
Page 736 11 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 737 11 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 738 11 Crane operation 11.5 Crane operation with main boom Unlocking • Select and confirm the symbol (1). The locking pins (2) are retracted. – Yellow: Intermediate position – Red: Unlocked – symbol (3) displayed 11 - 106 3 303 279 en Operating manual GMK5150XL...
Page 739 11 Crane operation 11.5 Crane operation with main boom Extending/ retracting the telescoping cylinder Prerequisites – Telescoping mechanism on – symbol (3) green – Telescopic sections locked – symbol (1) green – Telescoping cylinder unlocked – symbol (2) red Extending/retracting •...
Page 740 11 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 telescoping à...
Page 741 11 Crane operation 11.5 Crane operation with main boom Unlocking the Unlocking a telescopic section is required for the telescopic section to be telescopic section telescoped. The telescoping cylinder and the telescopic section cannot be unlocked simultaneously. Prerequisites – Telescoping mechanism on – symbol (3) green –...
Page 742 11 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 743 11 Crane operation 11.5 Crane operation with main boom Locking the Every telescopic section can be locked at the fixed lengths – fixed lengths; à telescopic section p. 11 - 97. Prerequisites – Telescoping mechanism on – symbol (3) green –...
Page 744 11 Crane operation 11.5 Crane operation with main boom Locking the Once you have retracted the main boom for on-road driving, you must lock telescopic section the telescoping cylinder in telescopic section I so that the axle loads are in à...
Page 745 11 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 telescoping direction. 2 Extend 3 Retract 4 Display in the case of return runs (without a telescopic section) Ending semi-automatic telescoping Teleautomation stops when the entered tele-...
Page 746 11 Crane operation 11.5 Crane operation with main boom Telescoping with No additional telescoping menu needs to be opened for this type of telescoping pre-selection operation. All displays are shown in the Monitoring RCL menu. Pre-selection of the telescope status was already performed when entering the rigging mode at à...
Page 747: High-Speed Mode
11 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 high-speed mode for a higher speed. Risk of accidents due to abruptly accelerating movements! Reduce the engine speed before starting high-speed mode. This prevents movements becoming excessively accelerated, which may result in the truck crane starting to sway and overturning.
Page 748: Continuous Operation
11 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 according to the Lifting capacity table (maximum degree of utilisation of 50%) before operating the hoists in high-speed mode.
Page 749: Slewing Gear
11 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 750 11 Crane operation 11.5 Crane operation with main boom Switching on the After the ignition is switched on, all power units are switched off and the lamps in slewing gear the corresponding buttons light up only dimly. • Press the button (1) – the lamp lights up brightly. Symbol (2) is green if the slewing gear is switched on.
Page 751 11 Crane operation 11.5 Crane operation with main boom Slewing The following requirements must be fulfilled before slewing: – The turntable is unlocked – provided systems are present à Unlocking the superstructure, p. 11 - 16 à Switching off the houselock, p. 11 - 19 à...
Page 752 11 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 the initial position, à the slewing movement slowly runs down; Braking the slewing movement, p.
Page 753 11 Crane operation 11.5 Crane operation with main boom Braking the You may only brake the slewing movement with the slewing gear brake. slewing movement Risk of the main boom buckling! Never switch the slewing gear off to brake it. Only switch the slewing gear off when the superstructure has stopped rotating.
Page 754: Switching The Slewing Speed Reduction On And Off
11 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 unintentional slewing gear use. Risk of damage to the main boom! Brake the slewing movement to a standstill before you switch off the slewing gear.
Page 755 11 Crane operation 11.5 Crane operation with main boom • Select and confirm the symbol (2). – Symbol (1) displayed – green. – Warning message display (3). The slewing speed is not reduced automatically. If the maximum permissible slewing speed is exceeded, the buzzer tone sounds once and the warning message (3) is displayed –...
Page 756: Possible Movement Combinations
11 Crane operation 11.5 Crane operation with main boom 11.5.10 Possible movement combinations – The main hoist, telescoping mechanism, derricking gear and slewing gear can be operated in almost any combination simultaneously. Restrictions are specified for the respective power unit. –...
Page 757: Settings And Displays For Crane Operation
11 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 operation. Operating elements that can be assigned to other procedures are described with the corresponding procedures.
Page 758: Setting The Idling Speed
11 Crane operation 11.6 Settings and displays for crane operation 11.6.2 Setting the idling speed à Setting the idling speed, p. 10 - 11 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 759: Limiting The Power Unit Speeds
11 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 menu (1) – Power unit speeds menu. The values below the symbols (1) to (6) indicate the currently set power unit speeds.
Page 760: Economy Mode
11 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 with Economy Mode switched on, when intervals A, B and C pass, three economy steps are activated in succession.
Page 761 11 Crane operation 11.6 Settings and displays for crane operation Setting the time interval • Select and confirm the symbol for interval (A) or (B). Change the value of the intervals using switch (1) or the buttons (2). You can set an interval from 10 seconds to 10 minutes.
Page 762: Switching Off
11 Crane operation 11.6 Settings and displays for crane operation Ending You can end Economy Mode in different ways. – Press the accelerator. – Increase the idling speed with the button. – Move a control lever (not after manual activation). –...
Page 763: Setting The Control Lever Characteristic Curve
11 Crane operation 11.6 Settings and displays for crane operation 11.6.7 Setting the control lever characteristic curve 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 764: Operating The Slewable Spotlights
11 Crane operation 11.6 Settings and displays for crane operation 11.6.8 Operating the slewable spotlights With the corresponding 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! Observe the position of the slewable spotlights before setting down the main boom.
Page 765 11 Crane operation 11.6 Settings and displays for crane operation Manually swinging Swing up • Press the button (1) at the top. Swing down • Press the button (1) at the bottom. The direction of the spotlights is adjusted until you let go of the button or they reach their end position.
Page 766: Overriding The Torque Reduction
11 Crane operation 11.6 Settings and displays for crane operation 11.6.9 Overriding the torque reduction A torque reduction can occur for various different reasons. – The AdBlue (DEF) supply is used up. – A system malfunction has been detected. Before the torque is automatically reduced, various messages are displayed on the CCS display, e.g.
Page 767: Cleaning The Exhaust System
11 Crane operation 11.6 Settings and displays for crane operation 11.6.10 Cleaning the exhaust system Risk of burns during the cleaning procedure! The exhaust system can heat to over 600 °C (1,110 °F) during automatic and manual cleaning. Keep away from the exhaust system and ensure that no persons on the carrier are in the vicinity of the exhaust system or exhaust pipe.
Page 768 11 Crane operation 11.6 Settings and displays for crane operation Manual cleaning You must perform manual cleaning if automatic cleaning is not performed in time. Depending on the degree of contamination of the exhaust system, manual cleaning needs to be performed within a certain time. Appropriate messages à...
Page 769 11 Crane operation 11.6 Settings and displays for crane operation Disabling cleaning Automatic cleaning cannot be performed and manual cleaning cannot be started when cleaning is disabled. This function is for sites where an exhaust tempera- ture higher than 600 °C (1,110 °F) poses a danger. At normal operating conditions, automatic cleaning is performed without interrupt- ing operation and is the best solution for the exhaust system.
Page 770: Displaying The Operating Hours
11 Crane operation 11.6 Settings and displays for crane operation 11.6.11 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 771: Working Range Limiter
11 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, –...
Page 772: Viewing Current Settings
11 Crane operation 11.7 Working range limiter 11.7.1 Viewing current settings On the RCL The displays show monitoring and speed limits that are switched on. display Working range limiter displays The corresponding symbol is shown when a monitoring system is switched on. 1 Hoist rope travel limitation monitoring 2 Overall height monitoring 3 Slewing angle monitoring...
Page 773: Opening The Working Range Limiter Menu
11 Crane operation 11.7 Working range limiter In the CCS Start The RCL shows the limited working range for the Slewing angle and Working radius menu 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 774: Entering Limit Values - For The Overall Height
11 Crane operation 11.7 Working range limiter 11.7.3 Entering limit values – for the overall height – For unknown limit values, you can approach a switch-off point and accept the current overall height as Accept limit value. – If the limit values are known, you can Manually enter limit value. Risk of accidents due to incorrectly set limit values! When entering the limit values, please note that movements leading further into the shutdown range can still take place even after switching off.
Page 775 11 Crane operation 11.7 Working range limiter Accepting the limit value • Move the main boom head to just before the shutdown point without a load, e.g. up to 17.5 m – (2) displayed. • Select and confirm the display (2). The current value (2) is accepted as the limit value (1).
Page 776: Entering Limit Values - For The Working Radius
11 Crane operation 11.7 Working range limiter 11.7.4 Entering limit values – for the working radius – For unknown limit values, you can approach a shutdown point and accept the current working radius as Accept limit value. – If the limit values are known, you can Manually enter limit value. Risk of accidents due to incorrectly set limit values! When entering the limit values, please note that movements leading further into the shutdown range can still take place even after switching off.
Page 777 11 Crane operation 11.7 Working range limiter Entering the limit value manually • (A) – Select and confirm the display (1). • (B) – Enter the limit value, e.g. 20.0 m and confirm the input. The display (1) shows the newly entered limit value.
Page 778: Entering Limit Values - For The Slewing Range
11 Crane operation 11.7 Working range limiter 11.7.5 Entering limit values – for the slewing range – For unknown limit values, you can approach a shutdown point and accept the current slewing angle as Accept limit value. – If the limit values are known, you can Manually enter limit value. Risk of accidents due to incorrectly set limit values! When entering the limit values, please note that movements leading further into the shutdown range can still take place even after switching off.
Page 779 11 Crane operation 11.7 Working range limiter Accepting the 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) is accepted as the limit value (2), for example, +17.6°.
Page 780 11 Crane operation 11.7 Working range limiter Switching on monitoring • Slewing range monitoring is switched on. The movement towards the shutdown limit is continuously reduced until reaching a standstill. The current limitation is displayed; à On the RCL display, p. 11 - 140, à...
Page 781: Entering Limit Values - For The Hoist Rope Travel
11 Crane operation 11.7 Working range limiter 11.7.6 Entering limit values – for the hoist rope travel The limit values for the hoist rope travel can only be entered by approaching the shutdown points. Manual input is not possible. Risk of accidents due to incorrectly set limit values! When entering the limit values, please note that movements leading further into the shutdown range can still take place even after switching off.
Page 782 11 Crane operation 11.7 Working range limiter Entering limit values The values for hoist rope limitation may not be entered until the telescope status and the boom position for the application have been rigged. If you change the telescope status or boom position after entering values for hoist à...
Page 783: Shutdown By Working Range Limiter
11 Crane operation 11.7 Working range limiter 11.7.7 Shutdown by working range limiter If a limit value is reached, an RCL shutdown will occur. All movements that would go closer to the limit value will be disabled. Shutdown remains active even if you switch off the monitoring function.
Page 784 11 Crane operation 11.7 Working range limiter Blank page 11 - 152 3 303 279 en Operating manual GMK5150XL...
Page 785: Work Break
11 Crane operation 11.8 Work break 11.8 Work break 11.8.1 At every work break Risk of accidents due to suspended loads! Never switch off the engine while a load is suspended. You must have the control levers at hand to be able to intervene at any time. Always set down the load before you leave the crane cab.
Page 786: For Every Work Break Longer Than 8 Hours
11 Crane operation 11.8 Work break 11.8.2 For every work break longer than 8 hours • Retract all telescopic sections. • Lower the main boom. • Switch off the slewing gear. – The lamp (1) must light up dimly. – The symbol (2) is orange – slewing gear switched off. –...
Page 787: Heating And Air-Conditioning System
11 Crane operation 11.9 Heating and air-conditioning system 11.9 Heating and air-conditioning system 11.9.1 Heating system Risk of explosion when operating the heating system! The heating system may not be operated: – At service stations and tank farms – At places where flammable gases or vapours can be found or formed (for example, at places where fuel is stored and in chemical factories), –...
Page 788 11 Crane operation 11.9 Heating and air-conditioning system Operating elements The heating is operated at the (2) control unit and at the UniControl (1) control unit. • Check whether the auxiliary air heater is permit- ted to be operated at the current site of the truck crane before switching it on.
Page 789 11 Crane operation 11.9 Heating and air-conditioning system • Press the button (1) – the lamp lights up green. à If the lamp flashes red; Error messages, p. 11 - 170. The heating system switches off and the display shows the Heating menu (2) with the currently set temperature.
Page 790 11 Crane operation 11.9 Heating and air-conditioning system Heating Air distribution You can direct the air to flow out of various air vents. • Turn the switch (4) to the desired position (1) – Air vents (A), (C), (B) or (D) (2) –...
Page 791 11 Crane operation 11.9 Heating and air-conditioning system Adjusting the air vents – Open/close Fold fins (1) in/out or turn (4) – Direct the air flow Swing the fins (1) Turn (2), (3) and (4) Setting fresh air / recirculated air –...
Page 792 11 Crane operation 11.9 Heating and air-conditioning system Heating • Switch the heating system on – lamp (1) green. • Switch the air-conditioning system off – lamp (3) gone out. • Turn the switch (4) to the desired level, e.g. to level 2. •...
Page 793 11 Crane operation 11.9 Heating and air-conditioning system Ventilating • Switch the heating system off – lamp (1) white. • Turn the switch (3) to the desired level, e.g. to level 2. • Switch to fresh air – lamp (2) gone out. •...
Page 794: Unicontrol Control Unit
11 Crane operation 11.9 Heating and air-conditioning system 11.9.2 UniControl control unit The crane cab heating and all auxiliary heaters on the carrier have one UniControl control unit each. Operation is identical for all heating systems. Before operation, observe all information in the section of the corresponding heating and carry out the steps given there before using the functions described here.
Page 795 11 Crane operation 11.9 Heating and air-conditioning system Displays and menus At the display 1 Activated preselection time 2 Time 3 Timer menu 4 Heating menu 5 Ventilation menu 6 Settings menu 7 Text display for selected menu Menu operation 1 Jog dial (rotary push button) –...
Page 796: Basic Settings
11 Crane operation 11.9 Heating and air-conditioning system Settings You can make various settings. à – Basic settings; p. 11 - 164. à – With the heating switched on; p. 11 - 165. à – With the heating switched off; p.
Page 797 11 Crane operation 11.9 Heating and air-conditioning system Setting the time • Select and confirm the Settings menu (2). • Select and confirm the Time symbol (1). The set time format (2) is displayed. • Select and confirm the desired time format. The hours of the time flash.
Page 798 11 Crane operation 11.9 Heating and air-conditioning system With the heating Different settings are possible, depending on the type of heating. switched off If you wait more than 5 seconds before confirming the setting, you must select the value again. With auxiliary air heating •...
Page 799 11 Crane operation 11.9 Heating and air-conditioning system For starting For starting manually, you can set whether to start the heating in Heating mode or manually in Ventilation mode. Setting the operating mode • Select and confirm the Settings menu (1). •...
Page 800 11 Crane operation 11.9 Heating and air-conditioning system For ventilating Ventilation operating mode is only available with the corresponding version. A maximum of thee parameters can be set. – Fan level (for the fan in the heater, is independent of the fan in the crane cabin) –...
Page 801 11 Crane operation 11.9 Heating and air-conditioning system The set values are displayed. – Day (1) – Switch-on time (2) – Switch-off time (3) – For auxiliary air heaters only – Heating mode (4) – Temperature (5) • Confirm the set values. The Activate symbol (1) is displayed.
Page 802: Error Messages
11 Crane operation 11.9 Heating and air-conditioning system Error messages Error messages are shown on the display and can be saved to an error log. – An error code with a T indicates an error at the UniControl control unit. –...
Page 803: Air-Conditioning
11 Crane operation 11.9 Heating and air-conditioning system 11.9.3 Air-conditioning 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 not exceed 10 °C to 14 °C (50 °F to 57.2 °F).
Page 804 11 Crane operation 11.9 Heating and air-conditioning system Switching on • Press the button (1) repeatedly until the lamp in the button lights up in white – heating off. • Press the button (2) repeatedly until the lamp under the button lights up – air-conditioning on. Cooling The air-conditioning is switched on –...
Page 805: Switching Off
11 Crane operation 11.9 Heating and air-conditioning system Drying the air The air-conditioning is switched on – lamp (5) lights up. • Press the button (1) repeatedly until the lamp in the button lights up in green – heating on. •...
Page 806 11 Crane operation 11.9 Heating and air-conditioning system Blank page 11 - 174 3 303 279 en Operating manual GMK5150XL...
Page 807: Telematic System
11 Crane operation 11.10 TELEMATIC system 11.10 TELEMATIC system Your truck crane is equipped with the TELEMATIC system. The TELEMATIC system is used to transmit crane data via mobile phone, thus allowing remote diagnostics and localisation of the truck crane. The TELEMATIC system works automatically, no controls need to be operated.
Page 808 11 Crane operation 11.10 TELEMATIC system Blank page 11 - 176 3 303 279 en Operating manual GMK5150XL...
Page 809: Rigging Work
12 Rigging work 12.1 Rigging work checklists for crane operation with the main boom Rigging work If the truck crane has already been rigged at the site, proceed according to the CHECKLIST: Checks before crane operation, p. 11 - 1. 12.1 Rigging work checklists for crane operation with the main boom...
Page 810 12 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 4. Fold up warning plates – if present; p. 5 - 10. 5. For rigging in the Free-on wheels operating position à – Check that the tyre pressure is correctly set; Maintenance manual.
Page 811 12 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 6. For rigging the truck crane on outriggers – Check that the ground can support the maximum outrigger pressures that à can occur; Determining the required load-bearing area, p. 12 - 11. –...
Page 812 12 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 8. Earth the truck crane, if necessary; Earthing the truck crane, p. 12 - 15. à 9. Fold out all ladders; p. 3 - 87. 10.
Page 813 12 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 14. Unlock the turntable – provided the systems are present à Unlocking the superstructure, p. 11 - 16 à Switching off the houselock, p. 11 - 19 15.
Page 814 12 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 20. Switch on spotlights as required. à – Switch on slewable spotlights; p. 11 - 132. à – Switch on spotlights I ; p. 9 - 155. à...
Page 815: Checklist: Unrigging
12 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 oper- ating instructions, which are indicated by cross-references. Observe the warnings and safety instructions given there! 1.
Page 816 12 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 6. For on-road driving with a dolly: – Make sure that the counterweight and holder have been removed from the à rear storage area; p. 12 - 113. –...
Page 817 12 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 11. Fold in all railings; p. 12 - 169. 12. Fold in or remove the mirror for crane operation; à Mirror for crane operation, p. 12 - 170. 13.
Page 818 12 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 16. Fold in all ladders; p. 3 - 88. 17. Switch on suspension (release locking) – symbol green (suspension on); à p. 5 - 19. 18.
Page 819: Choosing A Suitable Site
12 Rigging work 12.2 Choosing a suitable site 12.2 Choosing a suitable site Choose the position of your truck crane at the site with care. Observe the follow- ing aspects: – Check that the ground has sufficient load bearing capacity. You may need to à...
Page 820 12 Rigging work 12.2 Choosing a suitable site Load bearing capacity of the ground • Find the load bearing capacity of the ground using the table. Load bearing APPROXIMATE VALUES FOR THE LOAD BEARING capacity CAPACITY OF THE GROUND (t/m (lbs/ft Backfilled, not artificially compacted ground: 0 to 10...
Page 821 12 Rigging work 12.2 Choosing a suitable site Load-bearing area • Now calculate the required load-bearing area. à • Check that the area of the outrigger pad ( p. 1 - 19) is larger than the calcu- lated ground bearing area. If the area of the outrigger pad is smaller, you will need to increase the load-bearing area.
Page 822: Safe Distance From Slopes And Pits
12 Rigging work 12.2 Choosing a suitable site 12.2.2 Safe distance from slopes and pits Set up 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 backfilled ground, the safe distance (a) must be twice as...
Page 823: Earthing The Truck Crane
12 Rigging work 12.2 Choosing a suitable site 12.2.3 Earthing the truck crane The truck crane may become charged with static electricity. This may occur espe- cially when using outrigger pads made of synthetic material or when the outrigger pads are packed with insulating material (e.g. wooden planks). Risk of accidents due to electric shock! Earth the truck crane before you start to work with it –...
Page 824: Safe Distance From Overhead Power Lines
12 Rigging work 12.2 Choosing a suitable 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 accidents due to electric shock! The truck crane is not insulated.
Page 825 12 Rigging work 12.2 Choosing a suitable site For example, according to DIN VDE 0105 Voltage Safe distance (A) up to 1,000 V 1 m (3.3 ft) over 1,000 V to 110,000 V 3 m (9.8 ft) over 110,000 V to 220,000 V 4 m (13.1 ft) over 220,000 V to 380,000 V 5 m (16.4 ft)
Page 826 12 Rigging work 12.2 Choosing a suitable site Blank page 12 - 18 3 303 279 en Operating manual GMK5150XL...
Page 827: Rigging Work After Driving With A Dolly
12 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 while the truck crane is being driven, you must perform the following before working with the crane: à...
Page 828: Switching Off The Slewing Gear Freewheel
12 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, you must 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 829: Switching Off Boom Pre-Tensioning
12 Rigging work 12.3 Rigging work after driving with a dolly 12.3.3 Switching off boom pre-tensioning You must switch off boom pre-tensioning before you lift (raise) the main boom off the dolly. To switch off boom pre-tensioning, you must move the valves I to IV into the required positions, which will empty the pressure accumulator.
Page 830 12 Rigging work 12.3 Rigging work after driving with a dolly Blank page 12 - 22 3 303 279 en Operating manual GMK5150XL...
Page 831: Outriggers - Overview - Standard Slewing Range Type
12 Rigging work 12.4 Outriggers – Overview – Standard slewing range type 12.4 Outriggers – Overview – Standard slewing range type The information in this section applies only to the Standard slewing range type. If you want to operate the truck crane using the MAXbase slewing range type; à...
Page 832: Released Outrigger Spans
12 Rigging work 12.4 Outriggers – Overview – Standard slewing range type 12.4.2 Released outrigger spans Risk of overturning when slewing the superstructure! With some outrigger spans, slewing is only permissible with certain counter- à weight combinations and boom positions; Slewing with rigged counterweight, p.
Page 833: Outriggers - Overview - Maxbase Slewing Range Type
12 Rigging work 12.5 Outriggers – Overview – MAXbase slewing range type 12.5 Outriggers – Overview – MAXbase slewing range type The information in this section applies to the MAXbase slewing range type. If you want to operate the truck crane using the Standard slewing range type; à...
Page 834 12 Rigging work 12.5 Outriggers – Overview – MAXbase slewing range type Representation of the outrigger spans – Outrigger length The outrigger length ( I ) has a permanent value of 8.030 m (26.3 ft) and never changes. – Outrigger span All possible outrigger spans (1) to (5) are always shown for all outrigger beams.
Page 835: Representation In The Lifting Capacity Tables
12 Rigging work 12.5 Outriggers – Overview – MAXbase slewing range type 12.5.2 Representation in the lifting capacity tables The outrigger span is always specified in this form Outrigger length xxxx – outrigger span yyyyy – The value xxxx is always 8.030 m (26.3 ft). –...
Page 836 12 Rigging work 12.5 Outriggers – Overview – MAXbase slewing range type Front / Rear The outrigger span is the same at the front and the same at the rear – but different between the front and rear. The overall width is entered for the front and for the rear.
Page 837: Released Outrigger Spans
12 Rigging work 12.5 Outriggers – Overview – MAXbase slewing range type 12.5.3 Released outrigger spans Specific combinations are released for each type of outrigger span. This section shows all released combinations with the associated individual widths of the out- rigger beams.
Page 838 12 Rigging work 12.5 Outriggers – Overview – MAXbase slewing range type – Left greater than right The outrigger span is the same at the left and the same at the right. The table shows the permissible combinations. VR / HR VL / HL 3.350 m (11.0 ft) 3.800 m (12.5 ft)
Page 839 12 Rigging work 12.5 Outriggers – Overview – MAXbase slewing range type – Rear greater than front The rear outrigger beams are extended further than the front outrigger beams. The table shows the permissible combinations. VR / VL HR / HL 3.350 m (11.0 ft) 3.800 m (12.5 ft) 2.950 m (9.7 ft)
Page 840 12 Rigging work 12.5 Outriggers – Overview – MAXbase slewing range type – One outrigger span smaller – Right Three outrigger beams are extended the same distance and one outrigger beam has a smaller outrigger span. The table shows the released combinations.
Page 841: Outrigger Operation
12 Rigging work 12.6 Outrigger operation 12.6 Outrigger operation Danger of crushing by extending outrigger beams! You may only operate the outriggers if you yourself or a banksman with whom you are in visual contact have an unobstructed view of their movements. 12.6.1 CHECKLIST: Extending the outriggers This checklist is not a complete operating manual.
Page 842 12 Rigging work 12.6 Outrigger operation 5. Move the outrigger pads into the operating position and secure them; à p. 12 - 47. 6. Increase the load-bearing area if necessary; à Determining the required load-bearing area, p. 12 - 11, à...
Page 843: Checklist: Retracting The Outriggers
12 Rigging work 12.6 Outrigger operation 12.6.2 CHECKLIST: Retracting the outriggers This checklist is not a complete operating manual. There are accompanying oper- ating instructions, which are indicated by cross-references. Observe the warnings and safety instructions given there! à 1. Retract the supporting cylinders as far as possible; p.
Page 844: Preparing The Truck Crane
12 Rigging work 12.6 Outrigger operation 6. Switch off the engine; à – After operating it from the control units; p. 4 - 19. à – After operating it from the crane cab; p. 10 - 12. 12.6.3 Preparing the truck crane Driver's cab Levelling the truck crane •...
Page 845 12 Rigging work 12.6 Outrigger operation Switching over outrigger operation You can switch over operation of the outriggers between the Outrigger control units and the control units in the crane cab. • Open the menu (1) – Outrigger menu. Display –...
Page 846 12 Rigging work 12.6 Outrigger operation Blank page 12 - 38 3 303 279 en Operating manual GMK5150XL...
Page 847: Setting The Outrigger Spans
12 Rigging work 12.6 Outrigger operation 12.6.4 Setting the outrigger spans Extend the outrigger beams only as far as the permissible outrigger spans. Danger of overturning if the outrigger beams are not correctly extended! Extend the outrigger beams only as far as the permissible outrigger spans. Always extend all outriggers to the outrigger spans given in the Lifting capacity table for the planned application.
Page 848 12 Rigging work 12.6 Outrigger operation Overall width 6.700 m (22.0 ft) Individual width 3.350 m (11.0 ft) (A) – Requirements Pins (1) and (2) have been pulled out (B) – Setting and securing • Extend the outrigger beam up to the marking (3).
Page 849 12 Rigging work 12.6 Outrigger operation Overall width 5.100 m (16.8 ft) Individual width 2.550 m (8.4 ft) (A) – Requirements – Pin (1) has been pulled – Pin (2) has been inserted (B) – Setting and securing • Extend the outrigger beam up to the marking (3).
Page 850 12 Rigging work 12.6 Outrigger operation Blank page 12 - 42 3 303 279 en Operating manual GMK5150XL...
Page 851: Extending/Retracting Outrigger Beams
12 Rigging work 12.6 Outrigger operation 12.6.5 Extending/retracting outrigger beams Risk of accidents if outrigger beams cannot be seen! Cordon off the area where you intend to extend and retract the outrigger beams. Nobody is allowed to be in this area. Observe the moving outrigger beams or have them observed by a banksman who is in visual contact with you.
Page 852 12 Rigging work 12.6 Outrigger operation Switching on the lights Only the lamp (1) lights up after opening the door. • Press any button. The lights are switched on. • Check that the pins are removed/inserted as specified in the prerequisites for à...
Page 853 12 Rigging work 12.6 Outrigger operation Length specifications Percentages Lifting capacity Overall widths Individual widths Control unit table 7.600 m (25.0 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 (16.8 ft) 2.550 m (8.4 ft)
Page 854 12 Rigging work 12.6 Outrigger operation From the Operation must be switched over to the crane cab; à crane cab Switching over outrigger operation, p. 12 - 37. Starting the engine The parking brake is applied. à • Start the engine from the crane cab; p.
Page 855: Moving The Outrigger Pads Into Operating/Driving Position
12 Rigging work 12.6 Outrigger operation 12.6.6 Moving the outrigger pads into operating/driving position Moving them into operating 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 856 12 Rigging work 12.6 Outrigger operation Blank page 12 - 48 3 303 279 en Operating manual GMK5150XL...
Page 857: Enlarging The Load-Bearing Area
12 Rigging work 12.6 Outrigger operation 12.6.7 Enlarging the load-bearing area If the area of the outrigger pads is too small, you must enlarge the load-bearing à area by packing the outrigger pads; Determining the required load-bearing area, p. 12 - 11. For packing, only use suitable materials that will withstand the outrigger pressure, e.g.
Page 858 12 Rigging work 12.6 Outrigger operation Blank page 12 - 50 3 303 279 en Operating manual GMK5150XL...
Page 859: Extending/Retracting Supporting Cylinders
12 Rigging work 12.6 Outrigger operation 12.6.8 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 bear the resulting outrigger pressure. This prevents the ground under the outrigger pad giving way, causing the truck crane to tilt and overturn.
Page 860 12 Rigging work 12.6 Outrigger operation At the control Operation must be switched over to the Outrigger control units; à units Switching over outrigger operation, p. 12 - 37. Starting the engine • Start the engine. à – Either from the driver's cab; p.
Page 861 12 Rigging work 12.6 Outrigger operation From the crane The following operating elements are to be found in the Outrigger menu. Starting the engine à • Start the engine from the crane cab; p. 10 - 4. • Switch off the slewing gear. Opening the menu •...
Page 862: Levelling The Truck Crane On Outriggers
12 Rigging work 12.6 Outrigger operation 12.6.9 Levelling the truck crane on outriggers You must level the truck crane before crane operation and possibly correct its horizontal alignment during crane operation. Inclination After switching on the ignition, various inclination indicators show the current indicators alignment.
Page 863 12 Rigging work 12.6 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 standing higher at the rear right.
Page 864: Automatic Alignment
12 Rigging work 12.6 Outrigger operation à • Manual alignment Check that the prerequisites are met; p. 12 - 55. • Extend all supporting cylinders until none of the wheels is touching the ground. • Level the truck crane with the outriggers until only lamp (1) lights up in the à...
Page 865 12 Rigging work 12.6 Outrigger operation • Extend the supporting cylinders until the outrigger pads are just above the ground. Starting the procedure Depending on the equipment, you can start the procedure using the hand-held control and at the Outrigger control units. At the control units •...
Page 866: Levelling The Free-On-Wheels Truck Crane
12 Rigging work 12.6 Outrigger operation 12.6.10 Levelling the free-on-wheels truck crane This section describes levelling with the outrigger. You can also level the truck à crane using the axle raising option; p. 12 - 60. The suspension is switched off (locked) if the truck crane is in the Free on wheels operating position.
Page 867 12 Rigging work 12.6 Outrigger operation Switching on the suspension • Select and confirm the symbol (1) once. 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 horizon- tal alignment.
Page 868: Operating The Axle Raising System
12 Rigging work 12.6 Outrigger operation 12.6.11 Operating the axle raising system The axle raising system has two functions. – Raising/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 869 12 Rigging work 12.6 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 3 303 279 en 12 - 61 GMK5150XL...
Page 870: Outrigger Pressure Display
12 Rigging work 12.6 Outrigger operation 12.6.12 Outrigger pressure display Especially with asymmetrical outrigger spans, the outrigger pressure displays do not provide useful information on correct alignment. Horizontal alignment is the à decisive factor for correctly supporting the truck crane; p.
Page 871 12 Rigging work 12.6 Outrigger operation On the outrigger control units The assignment of the displays to the carrier corresponds to the top view. 1 Display for supporting cylinder 1.1 2 Display for supporting cylinder 2.1 3 Display for supporting cylinder 3.1 4 Display for supporting cylinder 4.1 Operating manual 3 303 279 en...
Page 872 12 Rigging work 12.6 Outrigger operation Blank page 12 - 64 3 303 279 en Operating manual GMK5150XL...
Page 873: Rigging/Unrigging The Counterweight
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7 Rigging/unrigging the counterweight For driving, parts of the counterweight must be set down on the counterweight platform, installed on the turntable or removed, depending on the driving mode; à Driving modes, p. 6 - 1 12.7.1 Information on rigging Rigging the counterweight is a challenging task.
Page 874 12 Rigging work 12.7 Rigging/unrigging the counterweight As the crane operator • Only use the Raise/lower hoist or Raise/lower derricking gear movements for set- ting down the counterweight. Execute the movements as slowly as possible. Notify the rigging personnel if the superstructure needs to be slewed for posi- tioning the counterweight.
Page 875: Counterweight Sections
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7.2 Counterweight sections The GMK5150XL can be equipped with a counterweight mass of 1.0 t (2,200 lbs) to 44.5 (98,100 lbs). There are various counterweight sections, depending on the truck crane's version and additional equipment. Version 1 This version enables you to drive with maximum axle loads of 12 t (26,500 lbs).
Page 876 12 Rigging work 12.7 Rigging/unrigging the counterweight Version 3 This version enables you to drive with maximum axle loads of 12 t (26,500 lbs). Counterweight – One 2.3 t base plate (1), – Two 2.3 t plates (2), – Three 4.6 t plates (3), –...
Page 877: Identification
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7.3 Identification The truck crane and its corresponding counterweight sections are labelled with the same serial number. Danger if counterweight sections are confused! Only use counterweight sections that belong to your truck crane. The truck crane and counterweight sections are labelled with the same serial number.
Page 878 12 Rigging work 12.7 Rigging/unrigging the counterweight The counterweight blocks are labelled with the serial number (1). 12 - 70 3 303 279 en Operating manual GMK5150XL...
Page 879: Slinging Points
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7.4 Slinging points Risk of accidents if used improperly! Attach the lifting gear to the various counterweight sections only at the appropri- ate slinging points and only use lifting gear of sufficient lifting capacity. Lift a maximum of two stacked 4.6 t plates.
Page 880 12 Rigging work 12.7 Rigging/unrigging the counterweight Blocks • Attach the blocks at the slinging points (1). 12 - 72 3 303 279 en Operating manual GMK5150XL...
Page 881: Checklist: Rigging The Counterweight
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7.5 CHECKLIST: Rigging the counterweight This checklist is not a complete operating manual. There are accompanying oper- ating instructions, which are indicated by cross-references. Observe the warnings and safety instructions given there! Danger of overturning when slewing with a rigged counterweight! Always check before slewing whether slewing is permitted in the truck crane's current rigging mode (counterweight, outrigger span, working radius).
Page 882: Checklist: Unrigging The Counterweight
12 Rigging work 12.7 Rigging/unrigging the counterweight 5. – Open the Counterweight menu, à – Correct the rigging mode, if necessary; p. 12 - 106, – Slew the superstructure into the rigging range and lift the counterweight in à automatic mode on to the turntable and pre-tension it; p.
Page 883 12 Rigging work 12.7 Rigging/unrigging the counterweight 3. – Open the Counterweight menu; à – Correct the rigging mode, if necessary; p. 12 - 106, – In automatic mode, lower the counterweight on to the counterweight à platform; p. 12 - 108. 4.
Page 884 12 Rigging work 12.7 Rigging/unrigging the counterweight Blank page 12 - 76 3 303 279 en Operating manual GMK5150XL...
Page 885: Assembling Counterweight Combinations
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7.7 Assembling counterweight combinations 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 outrigger span in the table in the section entitled Slewing with rigged counterweight, p.
Page 886 12 Rigging work 12.7 Rigging/unrigging the counterweight Setting down the 2.3 t base plate 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 in a central position on the carrier.
Page 887 12 Rigging work 12.7 Rigging/unrigging the counterweight Setting down the topmost counterweight section – for version 4 Risk of damage to the counterweight! Depending on the counterweight combination, position the 6.8 t blocks or the 6.9 t plate at the top. This prevents the lifting cylinders and counterweight being damaged while rigging.
Page 888 12 Rigging work 12.7 Rigging/unrigging the counterweight Version 1 The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 80 3 303 279 en Operating manual...
Page 889 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (5,071) (10,142) (5,071) (10,142) (5,071) (5,071) (2,205) (14,991) combination in t (lbs) ● – – – – – – – – – (2.200) ● ● –...
Page 890 12 Rigging work 12.7 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 82 3 303 279 en Operating manual...
Page 891 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (5,071) (10,142) (5,071) (10,142) (5,071) (5,071) (2,205) (14,991) combination in t (lbs) ● ● – – – ● – – ● – ● ● ● ●...
Page 892 12 Rigging work 12.7 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 84 3 303 279 en Operating manual...
Page 893 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (5,071) (10,142) (5,071) (10,142) (5,071) (5,071) (2,205) (14,991) combination in t (lbs) ● ● ● – – – – ● – ● ● ● ● –...
Page 894 12 Rigging work 12.7 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 86 3 303 279 en Operating manual...
Page 895 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (5,071) (10,142) (5,071) (10,142) (5,071) (5,071) (2,205) (14,991) combination in t (lbs) ● ● ● – ● – – ● – ● ● ● ● ●...
Page 896 12 Rigging work 12.7 Rigging/unrigging the counterweight Version 2 The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 88 3 303 279 en Operating manual...
Page 897 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (10,142) (5,071) (10,142) (20,283) (2,205) (14,991) combination in t (lbs) ● – – – – – – – (2.200) ● ● – – – – –...
Page 898 12 Rigging work 12.7 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 90 3 303 279 en Operating manual...
Page 899 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (10,142) (5,071) (10,142) (20,283) (2,205) (14,991) combination in t (lbs) ● ● ● – ● – ● – 19.4 (42.700) ● ● ● ● ● –...
Page 900 12 Rigging work 12.7 Rigging/unrigging the counterweight Version 3 The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 92 3 303 279 en Operating manual...
Page 901 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (10,142) (10,142) (5,071) (5,071) (2,205) (14,991) combination in t (lbs) ● – – – – – – – (2.200) ● ● – – – – –...
Page 902 12 Rigging work 12.7 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 94 3 303 279 en Operating manual...
Page 903 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (10,142) (10,142) (5,071) (5,071) (2,205) (14,991) combination in t (lbs) ● – – – ● – ● ● – – – – – ● ● ●...
Page 904 12 Rigging work 12.7 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 96 3 303 279 en Operating manual...
Page 905 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (10,142) (10,142) (5,071) (5,071) (2,205) (14,991) combination in t (lbs) ● – – – ● – ● ● – – – – – ● ● ●...
Page 906 12 Rigging work 12.7 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 98 3 303 279 en Operating manual...
Page 907 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (10,142) (10,142) (5,071) (5,071) (2,205) (14,991) combination in t (lbs) ● ● – – ● – ● ● ● – – – ● ● ● ●...
Page 908 12 Rigging work 12.7 Rigging/unrigging the counterweight Version 4 The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 100 3 303 279 en Operating manual...
Page 909 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (10,142) (15,212) (20,283) (2,205) (14,991) combination in t (lbs) ● – – – – – – (2.200) 3.3 t ● ● – – – – –...
Page 910 12 Rigging work 12.7 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counter- weight combinations that can be rigged. • Lift the counterweight sections on to the base plate; à Slinging points, p. 12 - 71. 12 - 102 3 303 279 en Operating manual...
Page 911 12 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counterweight (5,071) (5,071) (10,142) (15,212) (20,283) (2,205) (14,991) combination in t (lbs) ● ● – ● ● ● – 21.7 t (47.800) ● ● ● ● ● – –...
Page 912: Counterweight Hoist Unit
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7.8 Counterweight hoist unit The lifting cylinders (1) can be extended and retracted. To lift and lower the counterweight, the lifting cylinders are slewed 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 counterweight is being lifted or lowered.
Page 913 12 Rigging work 12.7 Rigging/unrigging the counterweight The Counterweight menu opens. Errors and warning messages can be shown during operation. 1 Slewing disabled – pre-tension the counter- à weight; p. 12 - 107. 2 Contact Grove Product Support 3 If the pre-tensioning pressure continues to drop, the message (1) appears.
Page 914 12 Rigging work 12.7 Rigging/unrigging the counterweight Correcting the rigging mode • You can only use automatic mode if the current rigging mode is displayed. A Counterweight rigged B Counterweight unrigged If necessary, correct the displayed rigging mode as follows: •...
Page 915 12 Rigging work 12.7 Rigging/unrigging the counterweight Pre-tensioning When the symbol (5) is red, you must pre-tension the counterweight. Slewing is disabled – symbol (2) is displayed. • Select and confirm the symbol (3) until the symbol (4) turns green. Slewing is enabled – symbol (1) is displayed.
Page 916 12 Rigging work 12.7 Rigging/unrigging the counterweight Switching on automatic mode • Select and confirm the symbol (3). Run automatic mode. • Move the slewing control lever in the displayed direction (1) or (2) – automatic mode starts. – The superstructure turns into position (A). –...
Page 917 12 Rigging work 12.7 Rigging/unrigging the counterweight Automatic In automatic mode, you can always unrigging à – Cancel automatic mode; Cancelling automatic mode, p. 12 - 110. – Interrupt automatic mode by letting go of the control lever. After moving the lever in the displayed direction once more, automatic mode is resumed.
Page 918 12 Rigging work 12.7 Rigging/unrigging the counterweight • Move the slewing control lever in the displayed direction (1) or (2) – automatic mode is resumed. – The superstructure turns into position (C). – The lifting cylinders are retracted (D). • Release the control lever.
Page 919: Removing/Installing The Counterweight On The Turntable
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7.9 Removing/installing the counterweight on the turntable Removal With version 1 and 3 two 2.3 t plates, and with version 2 and 4 one 9.2 t plate can be removed/installed on the turntable. Versions 1 and 3 •...
Page 920 12 Rigging work 12.7 Rigging/unrigging the counterweight Installing Versions 1 and 3 • Use automatic mode to lift the counterweight combination on to the turntable; à Automatic rigging, p. 12 - 107. • Push the clamps (2) through the bracket (3). •...
Page 921: Setting Down The Counterweight For Driving
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7.10 Setting down the counterweight for driving Which parts of the counterweight sections can be transported on the turntable and counterweight platform when driving the truck crane depends on the driving à mode of the truck crane; Driving modes, p.
Page 922 12 Rigging work 12.7 Rigging/unrigging the counterweight For driving with axle loads above 12 t (26,500 lbs) Risk of damage to the derricking cylinder! Set down the counterweight sections displayed here at the most and make sure that the 4.6 t blocks are always lying on the top on the 2.3 t plate. You thus prevent the derricking cylinder pressing against the 2.3 t plate and being damaged when the main boom is set down.
Page 923 12 Rigging work 12.7 Rigging/unrigging the counterweight • Place the holder (1) on the rear of carrier so that the retainers (2) mutually engage. Setting down the 4.6 t block • Place the 4.6 t block (4) on the holder (1) so that the retainers (5) mutually engage.
Page 924 12 Rigging work 12.7 Rigging/unrigging the counterweight Lifting the counterweight off the rear storage area • Lift the 4.6 t block off the holder. Risk of damage if the holder is set down Always lift the holder off the rear storage area before operating the crane. This prevents the counterweight from hitting the holder when turning and dam- aging the holder or causing it to fall off the rear storage area.
Page 925 12 Rigging work 12.7 Rigging/unrigging the counterweight Version 3 For driving with axle loads up to 12 t Installed on the turntable – 1.0 t plate (7) – or auxiliary hoist – 2.3 t plates (5) and (6) On the counterweight platform –...
Page 926 12 Rigging work 12.7 Rigging/unrigging the counterweight Blank page 12 - 118 3 303 279 en Operating manual GMK5150XL...
Page 927: Slewing With Rigged Counterweight
12 Rigging work 12.7 Rigging/unrigging the counterweight 12.7.11 Slewing with rigged counterweight Slewing with a rigged counterweight is only permitted when: – The necessary outrigger span is rigged, – The current rigging mode is shown on the RCL display and –...
Page 928 12 Rigging work 12.7 Rigging/unrigging the counterweight Blank page 12 - 120 3 303 279 en Operating manual GMK5150XL...
Page 929: Modifying The Auxiliary Hoist/1 T Plate
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8 Modifying the auxiliary hoist/1 t plate The auxiliary hoist (1) or the 1 t plate (2) must always be installed on the turntable. Risk of overturning while slewing! The weight of the auxiliary hoist or the 1 t plate is always added automatically by the RCL.
Page 930: Securing With A Guide Rope
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.2 Securing with a guide rope Risk of accidents due to swinging parts! Always secure the parts with a guide rope before lifting parts or separating any connections. This prevents you being caught or crushed by sections. Auxiliary hoist •...
Page 931: Checklist: Conversion To The Auxiliary Hoist
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.3 CHECKLIST: Conversion to the auxiliary hoist This checklist is not a complete operating manual. There are accompanying oper- ating instructions, which are indicated by cross-references. Observe the warnings and safety instructions given there! 1.
Page 932 12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate à 5. – Establish the hydraulic connections; p. 12 - 128. à – Establish the electrical connections; p. 12 - 129. à – Establish the connection to the central lubrication; p.
Page 933: Checklist: Switch Over To Installation On 1 T Plate
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.4 CHECKLIST: Switch over to installation on 1 t plate 1. – The superstructure is slewed to the front. – The main boom is resting in the boom rest. 2. Wind on the auxiliary hoist rope, using the rigging aid if necessary; à...
Page 934 12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 6. – Sling 1 t plate and secure it with a guide rope. à Weight; p. 1 - 13 à Slinging points, p. 12 - 121 à Securing with a guide rope, p. 12 - 122 –...
Page 935: Establishing/Separating The Connection Between Auxiliary Hoist And Turntable
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.5 Establishing/separating the connection between auxiliary hoist and turntable Risk of accidents due to swinging sections! Always secure the sections with a guide rope from the ground before establish- ing or separating connections. This prevents you being caught or crushed by sections.
Page 936: Establishing/Separating The Hydraulic Connection
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.6 Establishing/separating the hydraulic connection Establishing the connection The assignment is given by the size and colour designations. • Connect the hoses (1) to the connections (2). Removing the connection •...
Page 937: Establishing/Separating Electrical Connections
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.7 Establishing/separating electrical connections Establishing connections • Remove the plug (2) from the dummy socket (3) and plug it into the socket (1). • Close the dummy socket (3). • Insert the cable (4) for the hoist camera into the socket (5).
Page 938: Establishing/Separating The Connection To The Central Lubrication
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.8 Establishing/separating the connection to the central lubrication Establishing the connection • Connect the hose (1) to the connection (2) Removing the connection • Remove the hose (1) from the connection (2). •...
Page 939: Establishing/Separating The Connection Between 1 T Plate And Rotary Table
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.9 Establishing/separating the connection between 1 t plate and rotary table Risk of accidents due to swinging sections! Always secure the sections with a guide rope from the ground before establish- ing or separating connections.
Page 940: Transporting The Auxiliary Hoist/1 T Plate
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.10 Transporting the auxiliary hoist/1 t plate • For transport, only use a separate vehicle with sufficient load bearing capacity. Transport dimensions and weight; à , p. 1 - 12. à...
Page 941: Checking The Auxiliary Hoist For Correct Operation
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.11 Checking the auxiliary hoist for correct operation Slewing direction Check the slewing direction before attaching the hoist rope. Risk of accidents due to incorrect slewing direction Check after each installation that the slewing direction is correct. This prevents accidents caused by the hoist rope being wound up unexpectedly when it is applied.
Page 942: Rigging Aid For The Hoist Rope
12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate 12.8.12 Rigging aid for the hoist rope Depending on the equipment, the auxiliary hoist is provided with a rigging aid for the hoist rope. A connector (1) and a rope (2) belong to the rigging aid. Risk of damage to the hoist rope! Always rig the hoist rope with the rigging aid.
Page 943 12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate Rigging the hoist rope – When rigging • Guide the rope (1) over the main boom and over the upper head sheaves. • Slowly unreel the hoist rope. • Use the rope (1) to keep the hoist rope tensioned so that no slack rope occurs.
Page 944 12 Rigging work 12.8 Modifying the auxiliary hoist/1 t plate Blank page 12 - 136 3 303 279 en Operating manual GMK5150XL...
Page 945: Rigging Work On The Main Boom
12 Rigging work 12.9 Rigging work on the main boom 12.9 Rigging work on the main boom 12.9.1 Hook block on the bumper à When the hook block is transported on a separate vehicle; p. 12 - 139. Picking up the Depending on the driving mode, you must pick up the hook block from the front à...
Page 946 12 Rigging work 12.9 Rigging work on the main boom Attaching the Depending on the driving mode, you can attach the hook block to the front à hook block bumper; Driving modes, p. 6 - 1. Risk of accidents if the view is obstructed! The reeved rope lines obstruct the view of the runway.
Page 947: Hook Block On A Separate Vehicle
12 Rigging work 12.9 Rigging work on the main boom 12.9.2 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 948 12 Rigging work 12.9 Rigging work on the main boom Picking up the Depending on the driving mode, the hook block can be placed on a separate vehi- à hook block cle; Driving modes, p. 6 - 1. • If the respective setting has been made at the RCL, slew the superstructure and lower the main boom until the boom head is vertically above the hook block (1).
Page 949 12 Rigging work 12.9 Rigging work on the main boom • Remove the lifting limit switch weight (2) from à the hoist rope; p. 12 - 161. à • Unreeve the hoist rope; p. 12 - 149. • Secure the hook block (1) for transport. •...
Page 950: Reeving And Unreeving The Hoist Rope
12 Rigging work 12.9 Rigging work on the main boom 12.9.3 Reeving and unreeving the hoist rope You must reeve a certain number of rope lines, depending on the required load bearing capacity. Four reeved rope lines correspond, for example, to 4-fall reev- à...
Page 951 12 Rigging work 12.9 Rigging work on the main boom Risk of damage to the hoist rope! Always install the pocket lock as described in the following paragraph. This will prevent the hoist rope rubbing against the locknut and being damaged. Fastening the pocket lock to the main boom •...
Page 952 12 Rigging work 12.9 Rigging work on the main boom Reeving the hoist Depending on the equipment, you can use the rigging aid for fitting the hoist rope à rope if necessary; p. 12 - 134. Danger due to slack rope! Only use hook blocks and sling gear of the minimum weight prescribed in the Lift- ing capacity table depending on the reeving and boom length.
Page 953 12 Rigging work 12.9 Rigging work on the main boom Opening the hook block • Pull out the rods (1). • Fold down the plates (2). Rods for the rope guide • Remove the rod (5). • Remove the pin (3) and push the locking bar (4) to the rear.
Page 954 12 Rigging work 12.9 Rigging work on the main boom – For the auxiliary hoist rope • Push the rod (1) to the side and secure it. • Push the rod (2) to the side and secure it. • Guide the auxiliary hoist rope (4) under the rope grab (5).
Page 955 12 Rigging work 12.9 Rigging work on the main boom Fastening the hoist rope The fixed point used depends on the number of reeved rope lines. The fixed point (2) in the centre for the equipment with 6 head sheaves. –...
Page 956 12 Rigging work 12.9 Rigging work on the main boom Closing the hook block • Fold up the plates (2) on both sides. • Insert the rods (1) and secure them. Securing the hoist rope • Insert the rod (5) and secure it. •...
Page 957 12 Rigging work 12.9 Rigging work on the main boom Unreeving the hoist rope Opening the hook block • Pull out the rods (1). • Fold down the plates (2). Unreeving the hoist rope • Remove the rod (5). • Remove the pin (3) and push the locking bar (4) to the rear.
Page 958: Possible Reevings On The Main Boom
12 Rigging work 12.9 Rigging work on the main boom 12.9.4 Possible reevings on the main boom Possible reevings on lattice extensions and the auxiliary single-sheave boom top; à Lattice extension operating manual. The maximum lifting capacity is specified in the supplied Lifting capacity table. If the purpose and the rigging mode permit this, you should then select a 4-fall reeving compared to a 3-fall reeving.
Page 959 12 Rigging work 12.9 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 3 303 279 en 12 - 151 GMK5150XL...
Page 960 12 Rigging work 12.9 Rigging work on the main boom 3-sheave hook block Reeving 3-fall 1-sheave hook block Reeving 3-fall 2-fall 1-fall 12 - 152 3 303 279 en Operating manual GMK5150XL...
Page 961 12 Rigging work 12.9 Rigging work on the main boom Hook tackle Reeving 1-fall With 8 head With additional equipment, there may be 8 head sheaves. à sheaves With 6 head sheaves, p. 12 - 150. Depending on the reeving, you must place the head sheave in position (1) or (2) as shown in the reeving images in this section;...
Page 962 12 Rigging work 12.9 Rigging work on the main boom 8-sheave hook block Reeving 15-fall 14-fall 13-fall 12-fall 5-sheave hook block Reeving 11-fall 10-fall 9-fall 8-fall 12 - 154 3 303 279 en Operating manual GMK5150XL...
Page 963 12 Rigging work 12.9 Rigging work on the main boom 3-sheave hook block Reeving 7-fall 6-fall 5-fall 4-fall 3-sheave hook block Reeving 3-fall Operating manual 3 303 279 en 12 - 155 GMK5150XL...
Page 964 12 Rigging work 12.9 Rigging work on the main boom 1-sheave hook block Reeving 3-fall 2-fall 1-fall Hook tackle Reeving 1-fall 12 - 156 3 303 279 en Operating manual GMK5150XL...
Page 965 12 Rigging work 12.9 Rigging work on the main boom With 9 head sheaves 9-sheave hook block Reeving 18-fall Additional equipment only with special equipment Operating manual 3 303 279 en 12 - 157 GMK5150XL...
Page 966: Installing/Removing The Lifting Limit Switch
12 Rigging work 12.9 Rigging work on the main boom 12.9.5 Installing/removing the lifting limit switch à For the function of the lifting limit switch; p. 11 - 84. 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 967 12 Rigging work 12.9 Rigging work on the main boom If only one lifting limit switch is installed • Cover the unused socket with the protective cap (2). • Check whether the lock on the used lifting limit à switch, e.g. (1), is released; Releasing the lock, p.
Page 968 12 Rigging work 12.9 Rigging work on the main boom Attaching the lifting limit switch weight • Attach the lifting limit switch weight (1). This lifting limit switch must not be locked; à Releasing the lock, p. 12 - 163. If two hoist ropes are reeved, you must attach a lifting limit switch weight to each of the two lifting limit switches.
Page 969 12 Rigging work 12.9 Rigging work on the main boom Removing the This section describes the complete removal. lifting limit switch If the hook block is to be subsequently attached to the bumper, you only need to detach the lifting limit switch weight from the hoist rope in order to able to unreeve or re-reeve the hoist rope when unrigging.
Page 970 12 Rigging work 12.9 Rigging work on the main boom Removing the right lifting limit switch • Remove the plug (2) from the socket (1). • Seal the socket (1) with the cap. • Remove the lifting limit switch (3) from the clamp (4).
Page 971: Locking/Unlocking The Lifting Limit Switch
12 Rigging work 12.9 Rigging work on the main boom 12.9.6 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 from which the lifting limit switch weight is hanging is locked, release the lock.
Page 972: Anemometer And Air Traffic Control Light
12 Rigging work 12.9 Rigging work on the main boom 12.9.7 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 driv- ing. This prevents the specified overall height being exceeded at on-road level, and the anemometer being damaged due to unfavourable air currents.
Page 973 12 Rigging work 12.9 Rigging work on the main boom • Insert the rod (1) into the clamp (3) and secure it with the retaining pins • Remove the cable from the clamps (2). • Connect the plugs (4) to the sockets (5) – the assignment is defined by the version of the plugs.
Page 974 12 Rigging work 12.9 Rigging work on the main boom Removal You must remove the rod with the anemometer/air traffic control light before driv- ing on the road. • Switch off the air traffic control light. • Remove the plug and close the sockets (5) and (4) with the caps.
Page 975: Other Rigging Work
12 Rigging work 12.10 Other rigging work 12.10 Other rigging work 12.10.1 Rigging in free on wheels working position – The truck crane is supported on outriggers. – The counterweight combination required for using the truck crane free on wheels is rigged. •...
Page 976 12 Rigging work 12.10 Other rigging work Now lower all wheels to the ground. Horizontally aligning the truck crane Move the supporting cylinders evenly while leveling. Lower the truck crane only to the extent that the suspension struts still have enough play. •...
Page 977: Railing On The Turntable
12 Rigging work 12.10 Other rigging work 12.10.2 Railing on the turntable Risk of accidents if the railing is not pushed out! The railing provides protection against falling. Always fold out the railing before stepping on to the turntable. Risk of accidents due to exceeding the permissible dimensions Fold in the railing before driving.
Page 978: Mirror For Crane Operation
12 Rigging work 12.10 Other rigging work 12.10.3 Mirror for crane operation The mirror must be folded in or removed for driving. For crane operation or driving from the superstructure, the mirror must be installed and folded out. Risk of accidents due to exceeding the permissible dimensions Fold the mirror in or remove it for driving.
Page 979: Slinging Points For Personal Protective Equipment
12 Rigging work 12.10 Other rigging work 12.10.4 Slinging points for personal protective equipment The approved slinging points for the personal safety equipment are marked with special labels (3). • Always secure your personal safety equipment to the slinging points (1) and (2) when performing rigging work.
Page 980: Attachment Options For Fall Protection Device
12 Rigging work 12.10 Other rigging work 12.10.5 Attachment options for fall protection device The attachment options (2) and (3) are provided for the attachment of a fall protection device and are marked with a label (1). • Always secure yourself with an approved fall protection device.
Page 981: Cameras For Crane Operation
12 Rigging work 12.10 Other rigging work 12.10.6 Cameras for crane operation Cameras on the Depending on the equipment, the camera image is shown on the CCS display or hoists on a separate monitor. A camera can be found on both the main and auxiliary hoist (1).
Page 982 12 Rigging work 12.10 Other rigging work Risk of accidents if an incorrect transmitter or receiver is used! In the event of a defect, do not under any circumstances use a transmitter or receiver from another truck crane. This is to avoid the wrong image appearing on the monitor of your crane or the monitor of a neighbouring crane.
Page 983 12 Rigging work 12.10 Other rigging work Removal • Remove the plug (3) from the socket (4) and close it with the cap. • Remove the camera (1) from the clamp (2) and insert the retaining pin in the clamp (1). Camera on the driver's cab A camera (1) allows viewing of the non-visible...
Page 984: Operating The Camera
12 Rigging work 12.10 Other rigging work Operating the Depending on the equipment, the image is shown on the CCS display or on a sep- camera arate monitor. Switching on • Switch on the ignition. • (A) – Select and confirm the symbol (1) •...
Page 985 12 Rigging work 12.10 Other rigging work Switching off • (A) – Press button (1) or (2) once. • (B) – Press button (3) once. The image disappears. Operating manual 3 303 279 en 12 - 177 GMK5150XL...
Page 986: Step On The Crane Cab
12 Rigging work 12.10 Other rigging work 12.10.7 Step on the crane cab 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 987 12 Rigging work 12.10 Other rigging work Manual operation Risk of accidents during on-road driving due to the step moving out Always secure the retracted step using the spring latch. This prevents the step sliding out by itself during cornering. Pulling out the step •...
Page 988: Spotlights Iii
12 Rigging work 12.10 Other rigging work 12.10.8 Spotlights Spotlights III (1) are located on the carrier. The spotlights III can be pushed in and out. For crane You can push out the spotlight for crane operation and rigging mode. operation Pushing out •...
Page 989 12 Rigging work 12.10 Other rigging work For driving For driving mode you must push in the spotlight. Risk of accidents due to exceeding the permissible dimensions Push in the spotlight for driving mode. When the spotlight is pushed out, the overall width specified for on-road driving is exceeded.
Page 990 12 Rigging work 12.10 Other rigging work Blank page 12 - 182 3 303 279 en Operating manual GMK5150XL...
Page 991: Driving With A Rigged Truck Crane
13 Driving with a rigged truck crane 13.1 Driving distance Driving with a rigged truck crane This section describes how to drive the truck crane with the counterweight rigged. à If a lattice extension is also rigged; Lattice extension operating 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 banks- man who can observe the parts you are unable to see, for example, the erected...
Page 992: Permissible Rigging Modes And Axle Loads
13 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 993 13 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads Symbols in the table headers The symbols in the headers of the tables are used in this chapter. The RCL displays are shown for the truck crane’s rigging mode. The table gives an overview of the meaning.
Page 994 13 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads Max. in t (x 1000 lbs) in t in % in ° in ° (lbs) 14.5 14.0 0 - 0 - 0 - 0 - 0 - 0 5 - 65 180°...
Page 995 13 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads Max. in t (x 1000 lbs) in t in % in ° in ° (lbs) 17.0 18.0 0 - 50 - 50 - 0 - 0 - 0 5 - 50 180°...
Page 996 13 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads Blank page 13 - 6 3 303 279 en Operating manual GMK5150XL...
Page 997: For Driving Without A Load
13 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads 13.2.1 For driving without a load • Slew the superstructure to the 0° to the rear position – if slewing is not permitted in the current Free on wheels operating position then you must support the truck crane on outriggers before slewing.
Page 998: Axle Loads
13 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads • Switch to DM or RM transmission mode depending on the driving direction. Risk of accidents when driving with a lifted load! Secure the load when driving so that it cannot swing and use the DM or RM transmission mode so that the transmission does not shift.
Page 999: Before Driving The Rigged Truck Crane
13 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 • Make sure that all tyres have the prescribed inflation pressure; à...
Page 1000: Putting The Truck Crane On The Wheels - With Raise Axle Function
13 Driving with a rigged truck crane 13.3 Before driving the rigged truck crane 13.3.3 Putting the truck crane on the wheels – with raise axle function You can also use the outriggers to put the truck crane on the wheels; à...