Manitowoc GROVE GMK5150XL Manuals

Manuals and User Guides for Manitowoc GROVE GMK5150XL. We have 1 Manitowoc GROVE GMK5150XL manual available for free PDF download: Operating Manual

Manitowoc GROVE GMK5150XL Operating Manual

Manitowoc GROVE GMK5150XL Operating Manual (1128 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 45 MB

Table of Contents

Important Note
2
Table of Contents
11
Basic Safety Instructions
13
Overview
41
General Instructions
41
Accidents
41
Branch Offices
43
Dealer List
43
Warranty Information
43
Terms Used
44
Technical Data
47
Maximum Lifting Capacity (ASME B 30.5)
47
Dimensions and Weights of the Truck Crane, Axle Loads
48
Dimensions and Weights of Removable Parts
51
Carrier
57
Electrical System
60
Superstructure
61
Documentation Supplied
63
Questions on Documentation
64
Notes on the Operating Manual
65
What Do the Symbols Used Mean
65
How Is the Operating Manual Structured
67
How Do I Find the Information I Need
69
What Information Is Available for Operations Planning
72
Conversion Table for US Units of Measurement
73
Training - Information
75
Identification
76
EC Declaration of Conformity
78
Intended Use
80
Improper Use
81
Operating Elements for Driving
83
Overview - Notes
83
Overview - Exterior of the Truck Crane
84
Outrigger Control Units
89
Driver's Cab Overview
90
Front Overview
90
Rear Overview
92
Top Operating Elements
94
Left Operating Elements
96
Right Operating Elements
97
Centre Control Unit
98
Side Operating Elements
101
Steering Column/Steering Wheel Operating Elements
102
On-Board Computer Operating Elements
104
Heating and Air-Conditioning System Operating Elements
108
Auxiliary Heater
109
Door Operating Elements
110
Crane Control Operating Elements
112
CCS Control Unit
112
CCS - Menu-Dependent Displays
114
CCS - Start Menu
115
CCS - Overview of Menu Groups
116
Carrier Menu Group
118
Settings Menu Group
123
Information Menu Group
125
Various Controls Menu Group
129
Emergency Operations Menu Group
130
Brief Description of the Operating Elements
131
Definition of Direction Information
131
General Rules for Buttons and Symbols on the Display
132
Engine
133
Adblue (DEF) System
135
Exhaust Cleaning/Regeneration
135
Air Intake Inhibitor
137
Battery Master Switch
137
Electrical System
139
CCS Crane Control
140
Transmission
143
Reversing Camera
145
Birdview System 270
146
Switching off
147
Transfer Case
148
Final Drive
149
Brakes
150
Parking Brake
151
Steering
152
Separate Steering
152
Suspension
154
Lighting/Windscreen Wipers/Horn
155
Lights On/Off
158
Level Adjustment System
159
Tachograph/Speedometer
162
Diagnostics
163
On-Board Computer
164
Front Flap
166
Windows and Doors
167
Access Aids and Ladders
169
Starting the Engine / Switching It off - for Driving
173
Starting the Engine from the Driver's Cab
175
CHECKLIST: Starting the Engine
175
CHECKLIST: at Low Temperatures
178
Refuelling
179
Checks before Starting the Engine
182
Switching on the Ignition
183
Lamp Test/Synchronisation of the Switching States
184
Starting the Engine
185
Checks after Starting the Engine
187
Setting Idling Speed
189
Starting the Engine - at the Outrigger Control Units
190
Switching off the Engine
191
In the Driver's Cab
191
At the Outrigger Control Units
191
With Emergency Stop Switches
192
Air Intake Inhibitor
192
Driving Mode
195
Before Driving
195
CHECKLIST: Checks before On-Road Driving
195
Checking the Condition of the Truck Crane
202
Adjusting Mirrors
203
Adjusting the Seat and the Steering Column
208
Display - Adjusting the Brightness
211
Switching the Suspension On/Off
212
Setting the Tachograph
214
Setting the Time
218
Displaying and Resetting Operating Hours
219
Settings and Displays at the On-Board Computer
220
Operating the Transmission
235
Switching on
235
Switching the Transmission to Neutral Position
236
Selecting the Direction of Travel and Starting Gear
237
Changing the Operating Mode
239
Starting
240
Driving and Changing Gears
241
Changing the Driving Direction
243
Stopping
243
On the Roller Type Dynamometer
244
Warming up the Gear Oil
244
Driving the Truck Crane
245
Checks While Driving
245
Cruise Control
249
Switching off
250
Temposet
251
Driving Downhill
253
Driving Uphill
256
Overriding the Torque Reduction
257
Cleaning the Exhaust System
258
Manual Cleaning
259
Fold-Up Berth
261
Folding down
261
Off-Road Driving
263
Transfer Case - Switching the Off-Road Gear On/Off
264
Longitudinal and Transverse Differential Locks
265
Switching off
266
Operating the Level Adjustment System
267
Freeing a Truck Crane Stuck in Terrain
271
Separate Steering
273
Switching to Separate Steering
274
Switching to Normal Steering Mode
277
Switching off the Truck Crane
279
Every Time the Truck Crane Is at a Standstill
279
Every Time When Stationary for more than 8 Hours
280
When the Truck Crane Is Stationary for a Longer Period
281
Secure It against Moving Away
282
Heating and Air-Conditioning System
283
Standard Heating System
283
Air Distribution
284
Air-Conditioning System
288
Switching off
291
Auxiliary Water Heating System
292
Auxiliary Air Heater - Driver's Cab
295
Auxiliary Air Heater - Battery
297
Audio Device
298
Towing a Trailer
299
Coupling the Trailer
300
Driving Modes / Rigging for On-Road Driving
305
Driving Modes
305
Information on How to Use the Tables
306
Maximum Permitted Speeds with an Axle Load of over 12 T (26,500 Lbs)
310
Weighing the Truck Crane
311
Weighing Procedure
313
Rigging Work for Driving with a Dolly
315
Switching on the Slewing Gear Freewheel
316
Switching on the Boom Floating Position
317
Switching on Boom Pre-Tensioning
318
Raising/Lowering the 3Rd Axle Line
319
Rigging the Main Boom
321
CHECKLIST: Removing the Main Boom
322
CHECKLIST: Installing the Main Boom
325
Establishing/Breaking the Hydraulic/Electrical Connection
328
Derricking Cylinder Support
330
Slinging the Main Boom
330
Switching the Pressure Relief On/Off
333
Pulling/Fitting the Derricking Cylinder Head Axle
334
Extending/Retracting the Boom Pivot Pin
336
Transporting the Main Boom
339
Securing/Releasing the Derricking Cylinder
339
Aligning the Connecting Points
340
Checks after Installing the Main Boom
341
Removing/Installing the Outrigger Beams
343
CHECKLIST: Removing the Outrigger Beams
344
CHECKLIST: Installing the Outrigger Beams
346
Centre of Gravity Data
348
Preparations - for Removal
348
Preparations - on the Truck Crane
349
Removing/Attaching Outrigger Pads
350
Disconnecting/Establishing the Hydraulic Connection
352
Removing/Establishing the Electrical Connection
353
Unscrewing/Screwing in the Spacers
354
Separating/Establishing the Connections to the Supporting Box
356
Extending/Retracting the Outrigger Beams
356
Transporting the Outrigger Beams
360
Note on Error Messages with Removed Outrigger Beams
360
Transport
361
Transport with Transport Vehicle
361
CHECKLIST: Checks before Transport
362
Driving the Truck Crane on to the Transport Vehicle
365
Securing the Truck Crane against Slipping
366
Stopping the Truck Crane for Transport
367
Malfunctions in Driving Mode
369
Emergency Stop Switches
369
What to Do in the Event of Malfunctions
370
What to Do When a Malfunction Occurs in Road Traffic
370
Warning and Error Messages
371
Warning Messages on the Centre Control Unit
371
Engine Malfunction
374
Warning and Fault Messages on the On-Board Computer
375
Acknowledging Messages
376
Engine Messages
377
Transmission Messages
383
Brake System Messages
385
Maintenance Messages
389
Various Messages
390
Warning Messages on the CCS Display
391
Error Messages on the CCS Display
405
Troubleshooting
407
Malfunctions at the Engine
407
Malfunctions in the Transmission
408
Malfunctions of the Differential Locks
409
Transfer Case Malfunctions
409
Malfunctions of the Steering
410
Malfunctions at the Suspension
410
Malfunctions of the Level Adjustment System
410
Malfunctions in the Hydraulic System/Hydraulic Oil Cooler
411
Malfunctions at the CCS/RCL Control Units
411
Malfunctions at the Central Locking System
411
Emergency Operation and Breakdown Assistance
412
Externally Starting the Truck Crane
412
Battery Charger
413
Towing Away the Truck Crane
414
Compressed-Air Supply
415
Electric Power Supply
415
Final Drives
416
Switching off
416
Wheel Change
418
Mounting a Wheel
420
Inflating the Tyres Yourself
422
Emergency Operation for Steering 3Rd and 4Th Axle Line
424
Tilting/Lowering the Driver's Cab
429
Prerequisites and Information on Tilting
429
Tilting/Lowering the Driver's Cab
430
Fuses on the Carrier
435
Fuses in the Driver's Cab
436
Fuses in the Battery Box
442
Operating Elements for Crane Operation
443
Overview - Notes
443
Overview - Exterior of the Truck Crane
444
Hand-Held Control
448
Outrigger Control Units
449
Overview of Crane Cab
454
Side Panel Operating Elements
458
Rear Operating Elements
460
Control Panel Operating Elements
464
Control Lever Configuration
468
Right Control Lever
469
Heating and Air-Conditioning System Operating Elements
470
Crane Control Operating Elements
472
CCS Control Unit
472
CCS - Menu-Dependent Displays
474
CCS - Start Menu
475
CCS - Overview of Menu Groups
478
Superstructure Menu Group
482
Outriggers/Driving Menu Group
485
Rcl/Telescoping Menu Group
495
Active Working Range Limiter Menu Group
505
Information 1 Menu Group
510
Engine/Additional Equipment Menu Group
512
Remote Control Menu
514
Telescoping Emergency Program Menu Group
516
Settings Menu Group
519
Information 2 Menu Group
525
Various Controls
530
Query Menus
531
RCL Control Unit
532
Menu-Independent Displays
533
RCL Menus
534
Monitoring Menu
534
Lifting Capacity
536
Brief Description of the Operating Elements
537
Definition of Direction Information
537
General Rules for Buttons and Symbols on the Display
538
Engine
539
Adblue (DEF) System
541
Exhaust Cleaning/Regeneration
542
Air Intake Inhibitor
543
Seat Contact Switch and Dead Man's Switch
544
CCS Crane Control
545
Outrigger - Crane Cab
551
Outrigger Control Units
554
Raise Axle
557
Inclination Indicators
559
Outrigger Pressure Displays
560
Anemometer Displays
560
Counterweight Menu
561
Main Hoist
565
Auxiliary Hoist
567
Control Panels
567
Slewing Gear
569
Derricking Gear
571
Telescoping Mechanism
573
Hydraulic System
579
Superstructure Lock/Houselock Menu
580
Remote Control
583
Rated Capacity Limiter (RCL)
584
Current Position Display
585
Electrical System
596
Lighting, Windscreen Wiper/Washing System
597
Hand-Held Control
601
Windows and Doors
603
Rear Window
603
Diagnostics
605
Other
605
Short Description of the Operating Elements - Driving from the Crane Cab
607
Driving Menu
607
Transmission
609
Switch off
610
Final Drive
611
Brakes
612
Steering
613
10 Starting/Switching off the Engine - for Crane Operation
619
When Starting the Engine for the First Time in the Day
621
Starting the Engine - from the Crane Cab
622
Checking the Fuel Level and Adblue (DEF) Level
622
Checks before Starting the Engine
623
Switching on the Ignition
624
Control Lever Actuation Query
625
Synchronisation of the Switching States
626
Differential Locks
626
Display - Adjusting the Brightness
627
Starting the Engine
627
Checks after Starting the Engine
628
Setting the Idling Speed
629
Starting the Engine - with the Hand-Held Control
630
Switching off the Engine
630
From the Crane Cab
630
With the Hand-Held Control
631
After Switching off
631
Using the Emergency Stop Switches
632
Crane Operation
633
Before Operating the Crane
633
CHECKLIST: Checks before Crane Operation
633
Checking the Condition of the Truck Crane
637
Visual Inspection
637
Adjusting the Crane Cab Seat and Control Panels
640
Adjusting the Front Panel
641
Checking the Safety Devices
642
Rated Capacity Limiter
642
Earthing the Load
645
Prewarming Hydraulic Oil
646
Locking/Unlocking the Superstructure
647
Switching the Houselock On/Off
649
Setting the Time
652
Standard Slewing Range Type
653
Permissible Slewing Ranges and Operating Positions
653
Maxbase Slewing Range Type
655
Information in the Lifting Capacity Tables
656
Enabled Slewing Ranges
659
Lifting Capacities and Slewing Ranges for Outrigger Spans Without Separate Lifting Capacity
660
Operating the Rated Capacity Limiter
661
Switching on the RCL
662
Entering the Rigging Mode
664
Pre-Selecting Telescoping
672
Confirming the Rigging Mode and Lifting Capacity Table
673
Checks before Crane Operation
677
Displays During Crane Operation
681
Operating Position
686
RCL Early Warning
689
RCL Shutdown
689
Displaying the Lifting Capacity Tables
691
RCL Override - Version a
699
RCL Override - Version B
699
Datalogger
700
Crane Operation with Main Boom
705
Checks During Crane Operation
705
Horizontal Alignment
705
Main Hoist
709
Auxiliary Hoist
713
Lifting and Lowering
714
Lifting Limit Switch and Lowering Limit Switch
716
Derricking Gear
719
Raising and Lowering
720
Horizontal Position
722
Telescoping Mechanism
723
High-Speed Mode
747
Continuous Operation
748
Slewing Gear
749
Switching the Slewing Speed Reduction on and off
754
Possible Movement Combinations
756
Settings and Displays for Crane Operation
757
Inclining the Crane Cab
757
Setting the Idling Speed
758
Adjusting the Wiper Stroke Interval of the Windscreen Wiper
758
Limiting the Power Unit Speeds
759
Economy Mode
760
Switching off
762
Switching over Units
762
Setting the Control Lever Characteristic Curve
763
Operating the Slewable Spotlights
764
Overriding the Torque Reduction
766
Cleaning the Exhaust System
767
Displaying the Operating Hours
770
Working Range Limiter
771
Viewing Current Settings
772
Opening the Working Range Limiter Menu
773
Entering Limit Values - for the Overall Height
774
Entering Limit Values - for the Working Radius
776
Entering Limit Values - for the Slewing Range
778
Entering Limit Values - for the Hoist Rope Travel
781
Shutdown by Working Range Limiter
783
Work Break
785
At Every Work Break
785
For Every Work Break Longer than 8 Hours
786
Heating and Air-Conditioning System
787
Heating System
787
Unicontrol Control Unit
794
Basic Settings
796
Error Messages
802
Air-Conditioning
803
Switching off
805
TELEMATIC System
807
Rigging Work
809
Rigging Work Checklists for Crane Operation with the Main Boom
809
CHECKLIST: Rigging
809
CHECKLIST: Unrigging
815
Choosing a Suitable Site
819
Determining the Required Load-Bearing Area
819
Safe Distance from Slopes and Pits
822
Earthing the Truck Crane
823
Safe Distance from Overhead Power Lines
824
Rigging Work after Driving with a Dolly
827
Switching off the Boom Floating Position
827
Switching off the Slewing Gear Freewheel
828
Switching off Boom Pre-Tensioning
829
Outriggers - Overview - Standard Slewing Range Type
831
Representation in the Lifting Capacity Tables
831
Released Outrigger Spans
832
Outriggers - Overview - Maxbase Slewing Range Type
833
Definitions
833
Representation in the Lifting Capacity Tables
835
Released Outrigger Spans
837
Outrigger Operation
841
CHECKLIST: Extending the Outriggers
841
CHECKLIST: Retracting the Outriggers
843
Preparing the Truck Crane
844
Setting the Outrigger Spans
847
Extending/Retracting Outrigger Beams
851
Moving the Outrigger Pads into Operating/Driving Position
855
Enlarging the Load-Bearing Area
857
Extending/Retracting Supporting Cylinders
859
Levelling the Truck Crane on Outriggers
862
Automatic Alignment
864
Levelling the Free-On-Wheels Truck Crane
866
Operating the Axle Raising System
868
Outrigger Pressure Display
870
Rigging/Unrigging the Counterweight
873
Information on Rigging
873
Counterweight Sections
875
Identification
877
Slinging Points
879
CHECKLIST: Rigging the Counterweight
881
CHECKLIST: Unrigging the Counterweight
882
Assembling Counterweight Combinations
885
Counterweight Hoist Unit
912
Removing/Installing the Counterweight on the Turntable
919
Setting down the Counterweight for Driving
921
Slewing with Rigged Counterweight
927
Modifying the Auxiliary Hoist/1 T Plate
929
Slinging Points
929
Securing with a Guide Rope
930
CHECKLIST: Conversion to the Auxiliary Hoist
931
CHECKLIST: Switch over to Installation on 1 T Plate
933
Establishing/Separating the Connection between Auxiliary Hoist and Turntable
935
Establishing/Separating the Hydraulic Connection
936
Establishing/Separating Electrical Connections
937
Establishing/Separating the Connection to the Central Lubrication
938
Establishing/Separating the Connection between 1 T Plate and Rotary Table
939
Transporting the Auxiliary Hoist/1 T Plate
940
Checking the Auxiliary Hoist for Correct Operation
941
Rigging Aid for the Hoist Rope
942
Rigging Work on the Main Boom
945
Hook Block on the Bumper
945
Hook Block on a Separate Vehicle
947
Reeving and Unreeving the Hoist Rope
950
Possible Reevings on the Main Boom
958
Installing/Removing the Lifting Limit Switch
966
Locking/Unlocking the Lifting Limit Switch
971
Anemometer and Air Traffic Control Light
972
Other Rigging Work
975
Rigging in Free on Wheels Working Position
975
Railing on the Turntable
977
Mirror for Crane Operation
978
Slinging Points for Personal Protective Equipment
979
Attachment Options for Fall Protection Device
980
Cameras for Crane Operation
981
Operating the Camera
984
Changing Views
984
Step on the Crane Cab
986
Spotlights III
988
Driving with a Rigged Truck Crane
991
Driving Distance
991
Permissible Rigging Modes and Axle Loads
992
For Driving Without a Load
997
For Driving with a Load
997
Axle Loads
998
Before Driving the Rigged Truck Crane
999
Check the Tyre Pressures and Wind Speed
999
Secure the Superstructure against Slewing
999
Putting the Truck Crane on the Wheels - with Raise Axle Function
1000
Putting the Truck Crane on the Wheels - with the Outriggers
1002
Driving from the Driver's Cab
1005
Preparing to Drive
1005
While Driving
1006
After Driving
1007
Driving from the Crane Cab
1009
Preparing to Drive
1010
Releasing/Applying the Parking Brake
1011
Opening/Closing the Driving Menu
1012
During Crane Operation
1013
When Driving
1013
Closing the Menu
1014
Steering
1015
Operating the Transmission
1021
Selecting the Transmission Mode
1021
While Driving
1022
Transmission Modes
1022
Possible Connections
1023
After Driving
1025
Malfunctions During Crane Operation
1027
Emergency Stop Switch
1027
What to Do When Malfunctions Occur During Crane Operation
1028
Warning and Error Messages
1029
Warning Messages on the CCS Display
1029
Error Messages on the CCS Display
1031
Acknowledging Errors
1032
Warning Messages on the RCL Display
1034
Troubleshooting
1041
Malfunctions at the Engine
1041
Malfunctions on the Main Hoist/Auxiliary Hoist
1041
Malfunctions at the Main Boom Camera
1042
Malfunctions at the Hoist Cameras
1043
Malfunctions at the Derricking Gear
1043
Malfunctions at the Telescoping Mechanism
1044
Malfunctions at the Slewing Gear
1045
Malfunctions at Counterweight Hoist Unit
1046
Malfunctions When Operating with the Hand-Held Control
1046
Malfunctions When Raising the Axles
1046
Malfunctions at the Outriggers
1047
Malfunctions at the Hydraulic System/Hydraulic Oil Cooler
1047
Malfunctions at the CCS/RCL Control Units
1048
Malfunctions When Driving from the Crane Cab
1048
Emergency Operations and Programs
1049
Mechanical Emergency Activation for Retracting
1050
Telescoping Emergency Program
1053
Description of the Displays
1054
Entering the Current Telescoping
1066
Emergency Operation with the Hand-Held Control
1068
Emergency Operation
1072
Notes on Slewing in Emergency Operation
1074
Slewing with Overridden Slewing Gear Shutdown
1077
Hydraulic Emergency Operation with the Hand Pump
1079
Functionality
1079
Switching over the Crane's Hydraulic System
1080
Establishing the Required Hydraulic Circuits
1081
Performing Emergency Activation
1084
After Emergency Activation
1085
Hydraulic Emergency Operation According to DGUV
1087
Applications and Functionality
1087
Emergency Supply
1088
CHECKLIST: Emergency Operation
1089
CHECKLIST: after Emergency Operation
1090
Connecting/Removing the Transformer - for Self-Sufficiency
1091
Switching Emergency Operation On/Off
1093
Connecting/Removing the Transformer - for External Energy Source
1094
Establishing the Required Hydraulic Circuits
1095
Performing Emergency Operation
1099
Emergency Supply for Another Crane
1101
Fuses in the Crane Cab
1103
Operation
1117

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