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Manitowoc GROVE GMK5150L, Operating Manual

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Crane operation
11.5 Crane operation with main boom

11 - 80

3 302 709 en

Operating manual

GMK5150L

1

2

.0

1.

201

8

•

Check whether the current reeving of the auxiliary hoist is displayed, 
for example, 

6

. Correct the reeving if necessary; 

à

p. 11 - 39.

Lifting and 
lowering

You can adjust the sensitivity of the control levers to suit the operating 
conditions; 

à

Setting the characteristic curves for the control levers

, p. 11 - 129.

When the hoist drum is turning, you will notice a pulse on the slewing 
indicator (

1

). 

You can regulate the speed by moving the control lever and changing the 
engine speed with the accelerator. 

You can switch on high-speed mode for a higher speed; 

à

p. 11 - 113.

G

Risk of accidents due to gaps in monitoring

Operation of the hoist will only be monitored fully if:
– The lifting limit switch is correctly rigged; 

à

p. 12 - 139

– The lifting limit switch is not overridden; 

à

p. 11 - 82

– The lowering limit switch is correctly set; 

à

p. 11 - 82

G

Risk of accident by suspended loads

Never switch off the engine whilst a load is suspended. You must have the 
control levers at hand in order to intervene at any time. 
Always set down the load before you leave the crane cab.

Raising:

Pull the control lever to the rear – symbol (

3

) is displayed.

Lowering:

Pull the control lever to the front – symbol (

2

) is displayed.

Summary of Contents for GROVE GMK5150L

Page 1: ...Operating manual 3 302 709 en 12 01 2018 ...

Page 2: ...oc Crane Group Germany GmbH Industriegelände West D 26389 Wilhelmshaven Germany Phone 49 0 44 21 294 0 Fax 49 0 44 21 294 301 The passing on or reproduction of this document as well as the utilisation and disclosure of its contents is prohibited unless expressly permitted Infringement will incur liability for compensation All rights pertaining to registration of patent or utility model are reserve...

Page 3: ...nt crane types of what per cent you have to move the outrigger beams on the control units in order to obtain the desired outrigger span H Depending on the operating instructions supplied the outrigger spans are given as the overall width or additionally as an individual width s GMK5250L GMK5200 1 GMK5180 1 Length specifications Percentages Overall widths Individual widths Control unit Lifting capa...

Page 4: ... 2 ft 1 250 m 4 1 ft 0 0 GMK4100L 1 Length specifications Percentages Overall widths Individual widths Control unit Lifting capacity table 7 200 m 23 6 ft 3 600 m 11 8 ft 100 100 6 250 m 20 6 ft 3 125 m 10 3 ft 81 80 5 300 m 17 4 ft 2 650 m 8 7 ft 61 60 3 800 m 12 4 ft 1 900 m 6 2 ft 31 40 2 340 m 7 6 ft 1 170 m 3 8 ft 0 0 GMK3060 Length specifications Percentages Overall widths Individual widths ...

Page 5: ...ravel After switching over to driving position symbol 1 green the symbol 2 remains grey and the crane hydraulics driving position is switched off To carry out crane movements you can stop and switch over to the Crane operation operat ing mode as described in the supplied operat ing manual Driving from the crane cab Crane movement partially blocked ...

Page 6: ...12 01 2018 2 3 302 706 en Additional page GMK Blank page ...

Page 7: ...scopic cylin der 1 once the locking point 2 on the outermost telescopic section 3 has been reached There is no automatic shutdown B If you move too far past the locking point 2 the cylinder tube 4 will hit the main boom head 5 at the front This can lead to damage which makes telescop ing the main boom no longer possible Telescoping emergency programe Return run of the telescoping cylinder S Risk o...

Page 8: ...31 08 2018 2 3 302 808 en Additional pages GMK Blank page ...

Page 9: ...e hook blocks with ballast plates are no longer available A 3 sheave hook block light and a 1 sheave hook block light are offered as replacements The technical data in these additional pages apply Separable hook block The separable 5 sheave hook block 1 is unavailable The technical data in these additional pages apply to the separable 3 sheave hook block 2 s Hook blocks Change correction to the te...

Page 10: ...gle or double hook 5 sheaves 95 1 17 x 0 56 x 0 54 3 80 x 1 80 x 1 70 1 300 2 866 Single or double hook 3 sheaves heavy 60 1 00 x 0 56 x 0 44 3 20 x 1 80 x 1 40 950 2 094 Single or double hook 3 sheaves easy 60 0 92 x 0 56 x 0 44 3 00 x 1 80 x 1 40 700 1 543 Single or double hook 3 sheaves separable 60 1 30 x 0 62 x 0 44 4 20 x 2 00 x 1 40 950 2 094 Single or double hook 1 sheaves easy 26 0 92 x 0...

Page 11: ...3 22 11 2018 Versions as execution as separable hook block Section 1 2 3 Length in m ft 1 80 5 90 1 00 3 30 1 00 3 30 Width in m ft 0 65 2 15 0 60 1 95 0 65 2 15 Height in m ft 0 40 1 30 0 35 1 15 0 40 1 30 Weight in kg lbs 950 2 095 320 705 630 1 390 ...

Page 12: ...22 11 2018 4 3 302 834 en us Correction sheet GMK5150 GMK5150L Blank page ...

Page 13: ...e Various controls menu group only in newer program versions Operation The Crane cab heating air conditioning system menu is identical to the menu in the crane cab It is operated in the same way as in the crane cab and is described in the supplied operating manual After switching on the ignition in the driver s cab the heating system and air conditioning system in the crane cab must always be swit...

Page 14: ...28 11 2018 2 3 302 839 en Additional pages GMK Blank page ...

Page 15: ...ving 4 Starting the engine for driving switching it off 5 Driving 6 Driving modes and rigging for on road driving 7 Transport 8 Malfunctions in driving mode 9 Operating elements for crane operation 10 Starting switching off the engine for crane operation 11 Crane operation 12 Rigging work 13 Driving with a rigged truck crane 14 Malfunctions during crane operation 15 Index ...

Page 16: ...3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 17: ... Dimensions and weights of removable parts 1 10 1 5 4 Carrier 1 17 1 5 5 Superstructure 1 21 1 6 Documentation supplied 1 23 1 6 1 Questions on documentation 1 24 1 7 Notes on the operating manual 1 25 1 7 1 What do the symbols used mean 1 25 1 7 2 How is the operating manual structured 1 27 1 7 3 How do I find the information I need 1 29 1 7 4 What information is available for operations planning...

Page 18: ...3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 19: ...nstructions 2 1 Intended use 2 1 2 1 1 Improper use 2 2 2 2 Organisational measures 2 3 2 3 Personnel qualifications 2 5 2 4 Safety instructions for driving the truck crane 2 6 2 5 Safety instructions for crane operation 2 7 2 6 Instructions on transporting persons 2 10 ...

Page 20: ...3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 21: ... Various controls menu group 3 36 3 1 17 Emergency operations menu group 3 37 3 1 18 Outrigger control units 3 38 3 2 Short description of the operating elements 3 39 3 2 1 Definition of information relating to directions of movement 3 40 3 2 2 General rules for buttons and symbols on the display 3 41 3 2 3 Engine 3 42 3 2 4 AdBlue system 3 44 3 2 5 Battery master switch 3 45 3 2 6 Electrical syst...

Page 22: ...3 302 709 en Operating manual GMK5150L 12 01 2018 3 2 22 Front flap 3 73 3 2 23 Windows and doors 3 74 3 2 24 Access ladders and ladders 3 77 ...

Page 23: ...4 Checks before starting the engine 4 8 4 1 5 Switch the ignition on 4 9 4 1 6 Lamp test equalisation of the switching states 4 10 4 1 7 Display setting the brightness 4 11 4 1 8 Starting the engine 4 13 4 1 9 Checks after starting the engine 4 15 4 1 10 Setting the idling speed 4 17 4 2 Switch off the engine 4 18 4 2 1 At the ignition lock and with the outrigger control units 4 18 4 2 2 Using the...

Page 24: ...3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 25: ...g the driving direction 5 33 5 2 8 Stopping 5 33 5 2 9 On the roller type dynamometer 5 34 5 2 10 Preheating transmission 5 34 5 3 Driving the truck crane and switching it off 5 35 5 3 1 Checks whilst driving 5 35 5 3 2 Cruise control 5 38 5 3 3 Temposet 5 40 5 3 4 Driving downhill 5 41 5 3 5 Driving uphill 5 44 5 3 6 Overriding torque reduction 5 45 5 3 7 Switching the truck crane off 5 46 5 3 8 ...

Page 26: ...3 302 709 en Operating manual GMK5150L 12 01 2018 5 6 2 Air conditioning system 5 68 5 6 3 Auxiliary water heating system 5 70 5 6 4 Auxiliary air heater 5 76 5 7 Radio 5 80 5 8 Towing a trailer 5 81 ...

Page 27: ...racting fitting the derricking cylinder head pin 6 30 6 4 8 Extending retracting the boom pivot pin 6 32 6 4 9 Transporting the main boom 6 35 6 4 10 Securing releasing the derricking cylinder 6 35 6 4 11 Aligning the connecting points 6 36 6 4 12 Inspections after main boom mounting 6 37 6 5 Rigging the auxiliary hoist 6 39 6 5 1 Slinging the auxiliary hoist 6 39 6 5 2 CHECKLIST Installing the au...

Page 28: ...ing establishing hydraulic connection 6 60 6 6 8 Disconnecting establishing the electrical connection 6 61 6 6 9 Unscrewing screwing in the spacers 6 62 6 6 10 Disconnecting establishing the connections to the supporting box 6 64 6 6 11 Pulling out Inserting the outrigger beam 6 64 6 6 12 Transporting the outrigger beams 6 68 6 6 13 Note on error messages with removed outrigger beams 6 68 ...

Page 29: ... 3 302 709 en GMK5150L 12 01 2018 7 7 Transport 7 1 Transport with transport vehicle 7 1 7 1 1 CHECKLIST Checks before transport 7 2 7 1 2 Drive the truck crane on to the transport vehicle 7 4 7 2 Transport by ship 7 6 ...

Page 30: ...3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 31: ...tem 8 21 8 4 3 Differential lock malfunctions 8 22 8 4 4 Transfer case malfunctions 8 22 8 4 5 Malfunctions in the transmission 8 23 8 4 6 Malfunctions of the steering 8 24 8 4 7 Malfunctions of the service brake 8 25 8 4 9 Malfunctions of the level adjustment system 8 26 8 4 10 Malfunctions in the hydraulic system hydraulic oil cooler 8 26 8 5 Emergency operation and breakdown assistance 8 27 8 5...

Page 32: ...3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 33: ...up 9 59 9 1 16 Menu group settings 9 63 9 1 17 Information 2 menu group 9 69 9 1 18 Various controls 9 75 9 1 19 RCL control unit 9 76 9 1 20 Menu independent displays 9 77 9 1 21 RCL menus 9 78 9 1 22 Hand held control 9 83 9 1 23 Outriggers control units 9 85 9 2 Short description of the operating elements 9 89 9 2 1 Definition of information relating to directions of movement 9 89 9 2 2 General...

Page 34: ... 2 22 Rated capacity limiter RCL 9 133 9 2 23 Electrical system 9 145 9 2 24 Lighting windscreen wiper washing system 9 146 9 2 25 Hand held control 9 150 9 2 26 Windows and doors 9 154 9 2 27 Diagnostics 9 156 9 2 28 Other 9 156 9 3 Short description of the operating elements driving from the crane cab 9 157 9 3 1 Driving menu 9 157 9 3 2 Transmission 9 159 9 3 3 Final drive 9 161 9 3 4 Brakes 9 ...

Page 35: ...starting the engine 10 4 10 2 3 Switching the ignition on 10 5 10 2 4 Comparison of switching states 10 6 10 2 5 Display setting the brightness 10 6 10 2 6 Starting the engine 10 7 10 2 7 Checks after starting the engine 10 8 10 2 8 Setting the idling speed 10 9 10 3 Starting the engine with the hand held control 10 10 10 4 Switch off the engine 10 11 10 4 1 At the ignition lock and with hand held...

Page 36: ...3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 37: ...ut separate lifting capacity tables 11 28 11 4 Operation of the rated capacity limiter 11 29 11 4 1 Switch on the RCL 11 30 11 4 2 Enter rigging mode 11 32 11 4 3 Pre selecting telescoping 11 40 11 4 4 Confirm the rigging mode and lifting capacity table 11 41 11 4 5 Checks before operating the crane 11 45 11 4 6 Display during the crane operation 11 49 11 4 7 RCL early warning 11 57 11 4 8 RCL shu...

Page 38: ...7 Working range limiter 11 135 11 7 1 viewing current settings 11 136 11 7 2 Opening the working range limiter menu 11 137 11 7 3 Enter limit values for the overall height 11 138 11 7 4 Enter limit values for the working radius 11 140 11 7 5 Enter limit values for the slewing range 11 142 11 7 6 Enter limit values for the hoist rope travel 11 145 11 7 7 Shutdown by working range limiter 11 147 11 ...

Page 39: ...ntrol units 12 29 12 6 Slewing range only with the Standard slewing range type 12 31 12 6 1 Representation in the lifting capacity tables 12 31 12 6 2 Enabled outrigger spans 12 32 12 7 Outriggers Overview MAXbase slewing range type 12 33 12 7 1 Definitions 12 33 12 7 2 Representation in the lifting capacity tables 12 35 12 7 3 Enabled outrigger spans 12 36 12 8 Outrigger operation 12 41 12 8 1 CH...

Page 40: ... on the main boom 12 115 12 10 1 Hook block on the bumper 12 115 12 10 2 Hook block on a separate vehicle 12 117 12 10 3 Hook block separable 12 120 12 10 4 Hook block with ballast plates 12 122 12 10 5 Reeving and unreeving the hoist rope 12 124 12 10 6 Possible reevings on the main boom 12 132 12 10 7 Installing removing the lifting limit switch 12 139 12 10 8 Locking unlocking the lifting limit...

Page 41: ...rstructure against slewing 13 7 13 3 3 Putting the truck crane on the wheels with Raise axle function 13 8 13 3 4 Putting the truck crane on the wheels with the outriggers 13 10 13 4 Driving from the driver s cab 13 13 13 4 1 Preparing to drive 13 13 13 4 2 Whilst driving 13 14 13 4 3 After driving 13 15 13 5 Driving from the crane cab 13 17 13 5 1 Preparing to drive 13 18 13 5 2 Opening closing t...

Page 42: ...3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 43: ...ol 14 23 14 4 11 Malfunctions when inclining the crane cab 14 23 14 4 12 Malfunctions when raising the axles 14 23 14 4 13 Malfunctions of the outriggers 14 24 14 4 14 Malfunctions on the turntable lock 14 24 14 4 15 Malfunctions on the CCS RCL control units 14 25 14 4 16 Malfunctions when driving from the crane cab 14 25 14 4 17 Malfunctions on the CraneSTAR system 14 26 14 5 Emergency operations...

Page 44: ...mer for self sufficiency 14 63 14 7 5 Switching emergency operation on off 14 65 14 7 6 Connecting removing transformer for external energy source 14 66 14 7 7 Establishing the required hydraulic circuits 14 67 14 7 8 Performing emergency operation 14 71 14 7 9 Emergency supply of another crane 14 73 14 8 Fuses in the crane cab 14 75 ...

Page 45: ...Operating manual 3 302 709 en GMK5150L 12 01 2018 15 15 Index ...

Page 46: ...3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 47: ...f Manitowoc Crane Care in the country in which you are working and specify your crane type and serial number Observe to the requirements regarding the obligation to report accidents prevalent in the country in which you are working and inform the supervi sory authorities responsible for that particular type of accident for example material damage injuries to persons ...

Page 48: ...Overview 1 1 Accidents 1 2 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 49: ...port with the operation on your truck crane you can contact our branches at the following addresses Manitowoc Crane Care http www manitowoccranes com 1 2 2 Dealer list Visit the following address for a global list of dealers http www manitowoccranes com 1 3 Warranty specifications Please see the separately enclosed warranty certificate for information ...

Page 50: ...Overview 1 4 Terms used 1 4 3 302 709 en Operating manual GMK5150L 12 01 2018 1 4 Terms used ...

Page 51: ... 4 Axle lines 5 Outrigger beams 6 Outrigger cylinders 7 Outrigger pads B Superstructure 8 Slewing gear 9 Crane cab 10 Main boom with telescoping mechanism 11 Telescopic sections 12 Hook block 13 Derricking cylinder derricking gear 14 Telescoping cylinder 15 Turntable 16 Counterweight 17 Main hoist 18 Auxiliary hoist1 1 Additional equipment ...

Page 52: ...Overview 1 4 Terms used 1 6 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 53: ...issible temperature range 25 C to 40 C 13 F to 104 F Crane designation Truck crane as per DIN 15 001 Part 1 Crane application Service crane as per DIN 15 001 Part 2 Crane classification Hoist class H1 to DIN 15 018 Part 1 Crane class A1 to ISO 4301 Part 2 Max load bearing capacity Within the 360 slewing range 1 108 t 238 000 lbs 0 to the rear 1 130 t 286 000 lbs 0 to the rear 2 159 t 350 000 lbs M...

Page 54: ...Overview 1 5 Technical data 1 8 3 302 709 en Operating manual GMK5150L 12 01 2018 1 5 2 Dimensions and weights of the truck crane axle loads All dimensions in the illustration are in mm ...

Page 55: ...t 14 46 m 47 4 ft A Height 385 95 R25 445 95 R25 525 80 R25 Max level change At on road level 3 95 m 12 9 ft 3 99 m 13 1 ft 130 170 mm 5 1 6 7 in B Width 385 95 R25 445 95 R25 525 80 R25 2 75 m 9 0 ft 2 90 m 9 5 ft C Angle of negotiable banks Front Rear At on road level 385 95 R25 about 12 about 12 Total weight depending on driving mode 60 t 132 277 lbs Axle loads depending on driving mode 12 t 26...

Page 56: ...x 4 95 x 1 50 332 732 Spare wheel 525 80 R 25 1 50 x 1 50 x 0 53 4 92 x 4 92 x 1 74 362 798 Description Diameter x Height in m ft Weight in kg lbs Plastic outrigger pad diameter 0 50 x 0 16 1 64 x 0 52 25 55 Steel outrigger pad diameter 0 50 x 0 16 1 64 x 0 52 50 110 Front outrigger1 complete per packet 2 80 x 0 30 x 1 10 9 20 x 1 00 x 3 65 950 2 100 Rear outrigger1 complete per packet 2 80 x 0 35...

Page 57: ... separable hook block s Dimensions m and weights kg 1 2 3 4 5 6 Length 1 98 6 50 0 90 2 95 1 20 3 94 1 98 6 50 0 90 2 95 1 30 4 27 Width 0 70 2 30 0 70 2 30 0 70 2 30 0 70 2 30 0 70 2 30 0 70 2 30 Height 0 76 2 49 0 32 1 05 0 76 2 49 0 76 2 49 0 45 1 48 0 76 2 49 Weight in kg 960 2 116 275 606 685 1 510 1600 3 527 465 1 025 1135 2 502 ...

Page 58: ...k 3 sheaves 1 40 x 0 55 x 0 30 4 60 x 1 80 x 1 00 950 795 Single hook 1 sheave 1 35 x 0 55 x 0 25 4 45 x 1 80 x 0 82 500 465 Hook tackle 0 90 x 0 35 x 0 35 2 95 x 1 15 x 1 15 200 220 Description 1 x 2 x 3 in m Weight In kg Hook block 1 sheave with ballast plates 1 33 x 0 56 x 0 47 4 36 x 1 84 x 1 54 500 Hook block 1 sheave without ballast plates 1 33 x 0 56 x 0 20 4 36 x 1 84 x 0 65 325 1 ballast ...

Page 59: ... x 1 84 x 1 44 450 Hook block 1 sheave without ballast plates 1 41 x 0 56 x 0 35 4 63 x 1 84 x 1 15 325 1 ballast plate 19 Hook block 3 sheave with ballast plates 1 47 x 0 56 x 0 51 4 82 x 1 84 x 1 67 950 Hook block 3 sheave without ballast plates 1 36 x 0 53 x 0 30 4 46 x 1 74 x 0 98 440 1 ballast plate 25 Description Length x width x height in m ft Weight in kg lbs Complete auxiliary hoist 0 80 ...

Page 60: ...70 3 4 6 T block 1 76 x 0 93 x 0 59 5 77 x 0 28 x 1 94 4 600 10 140 4 4 6 T block 1 59 x 1 12 x 0 55 0 48 x 0 34 x 1 80 4 600 10 140 5 2 3 t plate 1 79 x 2 73 x 0 16 5 87 x 8 96 x 0 56 2 300 5 070 6 4 6 t plate 1 79 x 2 73 x 0 18 5 87 x 8 96 x 0 59 4 600 10 140 7 2 3 t plate 1 47 x 2 15 x 0 22 4 79 x 7 05 x 0 72 2 300 5 070 8 2 3 t plate 1 48 x 2 15 x 0 21 4 82 x 7 05 x 0 66 2 300 5 070 9 1 0 t pl...

Page 61: ...2 300 5 070 3 4 6 T block 1 76 x 0 93 x 0 59 5 77 x 0 28 x 1 94 4 600 10 140 4 2 3 t plate 1 79 x 2 73 x 0 16 5 87 x 8 96 x 0 56 2 300 5 070 5 4 6 t plate 1 79 x 2 73 x 0 18 5 87 x 8 96 x 0 59 4 600 10 140 6 9 2 t plate 1 81 x 2 73 x 0 65 5 93 x 8 96 x 2 15 9 215 20 315 7 1 0 t plate 1 00 x 0 65 x 0 26 3 28 x 2 15 x 0 78 1 000 2 205 8 à Auxiliary hoist p 1 13 9 6 8 T block 1 37 x 1 38 x 1 15 4 49 ...

Page 62: ...2 300 5 070 3 4 6 t plate 1 80 x 2 73 x 0 23 5 91 x 8 96 x 0 56 4 600 10 140 4 4 6 t plate 1 79 x 2 73 x 0 18 5 87 x 8 96 x 0 59 4 600 10 140 5 2 3 t plate 1 47 x 2 15 x 0 22 4 79 x 7 05 x 0 72 2 300 5 070 6 2 3 t plate 1 48 x 2 15 x 0 21 4 82 x 7 05 x 0 66 2 300 5 070 7 1 0 t plate 1 00 x 0 65 x 0 26 3 28 x 2 15 x 0 78 1 000 2 205 8 à Auxiliary hoist p 1 13 9 6 8 T block 1 37 x 1 38 x 1 15 4 49 x...

Page 63: ... 10 6 gal 1 For additional equipment 2 x 325 l 85 9 gal Drive 10 x 6 x 10 1 axle line Steered axle line 2 axle line Steered and driven axle line 3 axle line Steered axle line 4 axle line Steered and driven axle line steering can be switched on 5 axle line Steered and driven axle line Drive 10 x 8 x 101 1 axle line Steered axle line 2 axle line Steered and driven axle line 3 axle line Steered and d...

Page 64: ...on disc wheels 11 00 25 1 7 8 x 525 80 R 251 on disc wheels 17 00 25 1 7 Torque for wheel nuts 650 Nm 480 lbf ft Tyre pressure with cold tyres for axle loads up to max 12 t Turning turning radii All dimensions in the illustration are in mm 1 Additional equipment 385 95 R251 10 bar 145 psi 445 95 R25 9 bar 131 psi 525 80 R25 7 bar 102 psi 1 Michelin X Crane 9 bar 131 psi R values for normal steerin...

Page 65: ...x 19 4 ft 8 030 x 5 100 m 26 3 x 16 7 ft 8 030 x 2 500 m 26 3 x 8 2 ft 100 83 66 50 0 Outrigger span MAXbase à Enabled outrigger spans p 12 36 Outrigger pads Diameter 600 mm 23 6 in Surface 2 826 cm2 438 in2 Stroke of supporting cylinders 600 mm 23 6 in Maximum outrigger pressure Front 64 6 t 142 420 lbs Rear 74 2 t 163 583 lbs Inclination indicator In the crane cab at the outrigger control units ...

Page 66: ...port weight 60 t 132 277 lbs Alternator 28 V 100 A Batteries 2 each of 12 V 180 Ah Voltage 24 V Front towing coupling 100 kN 22 480 lbf permissible tension1 Rear tow lug 75 kN 16 860 lbf permissible tension1 1 Only permissible at certain tension angles à p 5 58 Forwards max 80 0 km h 49 7 mph Reverse about 6 km h 3 7 mph depending on the tyres Drive Climbing ability in off road gear with tyres 385...

Page 67: ...301 2 Load spectrum L 1 Load spectrum factor Km 0 125 Theoretical service life D 3 200 h Drum diameter 391 mm 15 39 in Rope diameter 19 mm 0 75 in Rope length 255 m 836 ft Rope pull 76 4 kN line 17 175 lbf Power unit group M 3 to ISO 4301 2 Load spectrum L 1 Load spectrum factor Km 0 125 Theoretical service life D 3 200 h Make Siebenhaar Type 01 DD Power unit group M2 to ISO 4301 2 Cylinder Differ...

Page 68: ...king unlocking mechanism Power unit group Telescoping mechanism M 1 to ISO 4301 2 1 Additional equipment Main hoist Rope speed when lifting Normal speed maximum 60 m min 197 ft min High speed mode maximum 120 m min 394 ft min Auxiliary hoist Rope speed when lifting Normal speed maximum 60 m min 197 ft min High speed mode maximum 120 m min 394 ft min Slewing gear 0 to 1 5 revolutions per minute wit...

Page 69: ...en the truck crane is supplied with additional equipment which is not described in the operating manual for driving and crane operation Documents from other manufacturers Original documentation for parts not manufactured by Manitowoc Crane Group Germany GmbH such as the engine and central lubrication system as well as the tachograph auxiliary heaters radio and where appropri ate other additional e...

Page 70: ...nt of spare parts Information about the position and quantity of plating 1 6 1 Questions on documentation Consult your dealer if you have questions on the documentation supplied for your truck crane You can find your responsible dealer here à 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 document...

Page 71: ... to the crane driver based on his prior knowledge of the individual operating steps and procedures 1 7 1 What do the symbols used mean The following designations and symbols are used in the operating manual and in the maintenance manual to highlight particularly important information The vertical line to the left of the hazards and warnings indicates that This text regardless of its length relates...

Page 72: ...xample The text used for examples is in a different font S This symbol indicates dangers which represent a hazard to objects for example damage to the truck crane or other parts which are located within the working range B This symbol warns you about situations where there is a danger of electric shock O This symbol is to remind you that you are working with substances which pose a risk to the env...

Page 73: ...ons For more extensive processes the description is given with checklist and operating instructions The checklists show the procedure in the required sequence for example for rigging work From there cross references take you to the correspond ing operation descriptions The operation descriptions describe the work in detail including the required warnings and safety instructions You are obliged to ...

Page 74: ... elements with parts of the truck crane or with pictograms Different methods of emphasis are used in the text column When a section is preceded by a hyphen as in this section for example you will find a list When a section is preceded by a bullet you will be required to take concrete action for example Shift the transmission to neutral The following text passages are highlighted in italics Designa...

Page 75: ...betic list of keywords and search terms with a reference to the relevant page in the operating manual Cross references are labelled with an arrow à and refer to other pages in the operating instructions These pages contain more detailed informa tion or information that relates to the topic in question Furthermore you can use the cross references to systematically familiar ize yourself with general...

Page 76: ...erating manual 1 30 3 302 709 en Operating manual GMK5150L 12 01 2018 Cross references example The illustrations texts and cross references in this section are only an example and may differ from the conditions on your truck crane ...

Page 77: ...s a cross reference in the form 2 Parking brake à p 3 52 C Page 3 52 gives a brief description of all the functions of the parking brake If further information is available the brief description contains a cross reference for example 4 Test posi tion for tow ing a trailer Pull the lever down until it locks into place Press in the lever and pull it further downwards The parking brake for the traile...

Page 78: ...fficient operation of the truck crane The operating manual contains Dimensions and weights of the truck crane à p 1 8 Driving modes permitted on public roads à p 6 1 Dimensions and weights of parts of equipment that can be removed à p 1 10 Turning radii à p 1 18 The permissible outrigger spans for the Standard slewing range type à p 12 32 The permissible outrigger spans for the MAXbase slewing ran...

Page 79: ... use US units of measurement Converting from into Multiply by mm into 0 03937 into mm 25 4 m ft 3 28084 ft m 0 30479 m2 ft2 10 76391 cm2 in2 0 155 cm3 in3 0 061 ltr gal US 0 264178 kg lbs 2 204622 lbs kg 0 45359 t lbs 2 204 622 lbs t 0 0004536 kN lbf 224 809 daN cm2 lbf in2 14 50378 lbf in2 daN cm2 0 06895 bar psi 14 50378 psi bar 0 06895 m s ft s 3 28084 km h or km mph or mi 0 62137 mph or mi km ...

Page 80: ...Overview 1 8 Conversion table for US measuring units 1 34 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 81: ...ur crane or else consolidates your specialist know how of sales marketing and service Our range of training programmes includes more than 20 different courses Take advantage of our services Training for prevention of accidents and crane operation Crane technology training Training tailored to your needs and level of experience for different levels of difficulty from beginner to specialist Theoreti...

Page 82: ...Overview 1 10 Identification 1 36 3 302 709 en Operating manual GMK5150L 12 01 2018 1 10 Identification ...

Page 83: ...sion is described in the correspond ing chapters or in the relevant operating manual provided 1 Serial number and crane type 2 The CE mark which is only applicable for truck cranes whose equip ment and configuration complies with the guidelines and standards specified in the supplied EC Declaration of Conformity 3 Driver s cab serial number at the strut of the door access 4 Chassis number and cran...

Page 84: ...s valid only if the truck crane complies with all of the guidelines and standards specified in the EC Declaration of Conformity This applies in particular to the programming and function of the overload protection Only then does the truck crane receive a CE mark upon delivery The Declaration of Conformity shall become invalid and the CE mark must be removed if any modifications that do not comply ...

Page 85: ...ately The GMK5150L truck crane may only be operated without the corre sponding special equipment within the permitted temperature range à Technical data p 1 7 The GMK5150L truck crane is designed solely for lifting loads which are within the permitted GMK5150L lifting capacities The load must be slung as prescribed to a hook block which is positioned vertically over the load prior to lifting Inten...

Page 86: ...ation on the main boom head without additional equipment Setting RCL codes that do not correspond to the actual rigging mode Working with an overridden RCL or overridden lifting limit switch After RCL shutdown increasing the working radius by pulling the raised load at an angle e g with a chain hoist Misuse of the outrigger pressure display as a safety function to prevent the crane from overturnin...

Page 87: ... regulations concerning the operation of a crane Make sure that persons who will work on the truck crane are provided with the required information prior to starting operations Instruct your person nel e g banksmen slingers rigging personnel accordingly Make sure the maintenance personnel have the necessary expertise for safe crane operation Make sure the maintenance personnel have access to the o...

Page 88: ... safety This also applies to Installation of safety devices Adjustment of safety devices and valves All welding work especially on load carrying members may only be per formed by qualified professional personnel with the prior written permis sion of Manitowoc Crane Group Germany GmbH To avoid damage especially to electronic parts there are certain measures you must take before doing any welding wo...

Page 89: ...itly for crane operators who have been trained to operate truck cranes Personnel in training may only operate the truck crane under supervision Only reliable personnel may operate or carry out work on the truck crane As a crane operator you must fulfil a number of requirements You must possess a driving licence for this type of vehicle that is valid in the country in which you are working You must...

Page 90: ... you start the vehicle Check the condition of the truck crane carefully using the checklists in the operat ing manual Do not assume everything is in working order simply because it was in working order at the end of the last shift Check that all covers and safety devices are fitted properly and that they are in good condition before starting the vehicle Use the appropriate access aids when checkin...

Page 91: ...ume everything is in working order simply because it was in working order at the end of the last shift Check daily that all covers and safety devices are fitted properly and are in good condition before crane operation Check the safety devices RCL lifting limit switch dead man s switch emergency stop switches every day before you start work Use the appropriate access aids when carrying out overhea...

Page 92: ...ea clearly and mark the area as such When lifting a load balance out the increase in working radius caused by flexure of the boom by raising the boom so that the load is lifted vertically and does not drag injure helpers or topple into the hoist rope e g from a vehicle or scaffolding Inform any banksmen and helpers about this issue as well Support the truck crane with the outrigger span required f...

Page 93: ...nity of live overhead power lines as well as oil gas or other pipelines is dangerous and requires special precautionary measures Please observe the instructions in the section titled Crane operation under special operating conditions in the Safety manual and the respective national regulations Testing the truck crane by lifting an excessively heavy load overload test ing is prohibited This present...

Page 94: ...ddition to the provisions of in this section always also observe the legal requirements and guidelines for transporting persons applicable in the country in which you are working Further information on transporting persons can be found under the address http fem eur com Equipment for lift ing persons When lifting persons only use equipment for lifting persons that comply with the requirements spec...

Page 95: ...orking order Before transporting persons the crane operator must make sure that the lifting limit switch is not overridden The operating manual and the lifting capacity table must be in the crane cab and in easy reach of the crane operator All crane movements must be performed slowly and with extreme care The crane operator is not allowed to leave the crane cab until the equipment for lifting pers...

Page 96: ...nt for lifting persons is being used and is in a stationary position then the slewing gear hoist derricking gear and telescoping mechanism must be secured against accidental use by being switched off Truck crane The truck crane must be equipped e g with hydraulic emergency opera tion so that the equipment for lifting persons can be set down and the persons being transported can safely leave it eve...

Page 97: ... are described in Chapter 9 3 1 Overview of the operating elements This section shows the position and designation of the operating elements for driving This also includes display elements such as lights or displays H Operating elements available only with additional equipment are desig nated accordingly These designations are made in this section only and are not repeated in the following section...

Page 98: ...Operating elements for driving 3 1 Overview of the operating elements 3 2 3 302 709 en Operating manual GMK5150L 12 01 2018 3 1 1 On the outside of the truck crane ...

Page 99: ...Third brake light At the rear of carrier storage compartment1 Third brake light At the spare wheel clamp1 à p 8 33 à p 5 81 à p 5 12 à p 8 35 9 BirdView system 270 Camera1 à p 3 53 10 Chocks1 à p 5 46 11 Storage space for the folding ladder à p 3 77 12 Outriggers Operation Lighting Installing removing the outrigger beams à p 12 41 à p 12 45 à p 6 51 13 Swing out ladders à p 3 77 14 Fuel tank Dual ...

Page 100: ...Operating elements for driving 3 1 Overview of the operating elements 3 4 3 302 709 en Operating manual GMK5150L 12 01 2018 ...

Page 101: ...g position1 à p 6 13 à p 12 19 23 Switching on boom pre tensioning1 Switching off boom pre tensioning1 à p 6 14 à p 12 21 24 Shut off valves at the hydraulic tank à p 4 8 25 Hydraulic emergency operation with the hand pump Hydraulic emergency operation acc to BGR 1591 à p 14 51 à p 14 59 26 Hydraulic oil cooler second cooler1 27 Warning plates for vehicle width1 à p 5 9 28 Driver s cab tilt mechan...

Page 102: ...Operating elements for driving 3 1 Overview of the operating elements 3 6 3 302 709 en Operating manual GMK5150L 12 01 2018 3 1 2 Driver s cab Front overview ...

Page 103: ...7 à p 5 8 12 Adjusting the air vents à p 5 66 13 Cab lighting à p 3 67 14 Instrument panel Left right à p 3 11 15 Steering column steering wheel à p 3 10 16 Tachograph or cover à p 3 16 17 Battery heating1 2 18 Instrument panel Middle à p 3 12 19 Auxiliary water heating system1 à p 3 18 20 Radio USB 1 2 à p 5 80 21 Auxiliary water heating system1 à p 3 18 22 Heating and air conditioning system à p...

Page 104: ...erview of the operating elements 3 8 3 302 709 en Operating manual GMK5150L 12 01 2018 Rear overview 1 Fold up berth1 à p 5 48 2 Rest 3 Storage spare key etc on delivery 4 Storage compartment e g for battery charger 1 Additional equipment ...

Page 105: ...Operating elements for driving 3 1 Overview of the operating elements Operating manual 3 302 709 en 3 9 GMK5150L 12 01 2018 Behind the cover 1 Fuses in the driver s cab à p 8 50 ...

Page 106: ...idling speed Setting cruise control Setting the Temposet Engine retarder transmission retarder1 Hands free unit2 à p 3 42 à p 3 43 à p 3 43 à p 3 58 3 Horn à p 3 65 4 Headlight flasher headlight full beam Turn signal indicator wiper washing system à p 3 65 à p 3 65 5 Transmission operating elements à p 3 14 6 Ignition lock à p 3 42 7 Adjusting the steering column à p 5 15 1 Additional equipment 2 ...

Page 107: ...ight s 1 Lighting on off à p 3 66 2 Separate manual steering à p 3 61 3 Battery master switch à p 3 45 4 Heating system à p 3 17 5 Hazard warning system on off à p 3 66 6 Dual tank à p 4 6 7 Override torque reduction à p 3 44 8 Rotating beacon on off à p 3 67 9 Air conditioning system1 à p 3 17 10 12 V power socket on off à p 3 46 1 Additional equipment ...

Page 108: ...Operating elements for driving 3 1 Overview of the operating elements 3 12 3 302 709 en Operating manual GMK5150L 12 01 2018 Middle ...

Page 109: ...high warning à p 3 43 9 Brake malfunction à p 3 58 10 ABS warning à p 5 35 11 Display Time Outdoor air temperature à p 3 73 à p 3 73 12 Checking headlight full beam à p 3 65 13 Check the retarder 14 Clutch indicator à p 3 51 15 Parking brake indicator lamp à p 3 60 16 Parking light indicator à p 3 66 17 Kilometre counter à p 3 70 18 Fuel level display à p 4 5 19 Steering system warning à p 3 61 20...

Page 110: ...of the operating elements 3 14 3 302 709 en Operating manual GMK5150L 12 01 2018 3 1 5 Transmission operating elements 1 Selecting the driving direction à p 3 49 2 Changing the operating mode 3 Shift down manual 4 Shift up manual 5 Gear indicator ...

Page 111: ...iving 3 1 Overview of the operating elements Operating manual 3 302 709 en 3 15 GMK5150L 12 01 2018 3 1 6 On board computer 1 Main menu display à p 3 72 2 Display menu Name 3 Submenu display 4 Display area 5 Display information ...

Page 112: ...ph1 à p 5 18 1 Display à p 5 21 2 Time correction à p 3 70 3 Time correction à p 3 70 4 Opening the drawer à p 5 19 5 Setting the time group driver 1 à p 5 20 6 Setting the time group driver 2 à p 5 20 7 Correction of time à p 3 70 8 Drawer à p 5 19 B Cover1 9 Time correction à p 3 70 10 Time correction à p 3 70 1 A or B present depending on the version ...

Page 113: ...ments Operating manual 3 302 709 en 3 17 GMK5150L 12 01 2018 3 1 8 Heating and air conditioning system Standard s 1 Setting the fan à p 5 65 2 Air distribution à p 5 66 3 Setting the temperature à p 5 65 4 Air conditioning system à p 5 68 5 Setting the fan à p 5 65 ...

Page 114: ... 1 Overview of the operating elements 3 18 3 302 709 en Operating manual GMK5150L 12 01 2018 Auxiliary water heating system 1 Auxiliary water heating system Preheating the engine Preheating the driver s cab à p 5 70 à p 5 70 à p 5 71 ...

Page 115: ...he operating elements Operating manual 3 302 709 en 3 19 GMK5150L 12 01 2018 Auxiliary air heater 1 Selecting a function à p 5 76 2 Menu line 3 Program column 4 Display line 5 Switching on Switching off à p 5 76 à p 5 80 6 Confirm the entry à p 5 76 ...

Page 116: ...Operating elements for driving 3 1 Overview of the operating elements 3 20 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 117: ...nnection1 à p 3 71 3 Exiting the menu input mode à p 3 47 4 Selector buttons à p 3 47 5 Selecting deselecting favourites à p 3 49 6 Sensor for brightness à p 3 48 7 Overview menu groups Operation Overview menu groups Overview à p 3 48 à p 3 24 8 Input confirmation à p 3 47 9 no function 10 Display temperature warning display à p 3 48 1 For Service personnel only not suitable for external devices e...

Page 118: ...18 3 1 10 CCS menu dependent displays 1 Transverse differential locks display Longitudinal differential lock display à p 3 57 à p 3 57 2 Display of retarder function on off à p 5 43 3 Suspension display à p 3 64 4 Transfer case display à p 3 55 5 Display area for error and warning messages à p 8 13 6 Display time à p 3 30 ...

Page 119: ...lay of crane type 2 Serial number display 3 Display of transverse and longitudinal differential locks on off à p 3 28 4 Voltage monitoring display à p 4 15 5 Hydraulic oil temperature display à p 4 15 6 AdBlue level display à p 4 15 7 Display of current inclination à p 3 69 8 Steering mode display à p 3 62 9 Steering system malfunction warning à p 3 62 ...

Page 120: ...Operating elements for driving 3 1 Overview of the operating elements 3 24 3 302 709 en Operating manual GMK5150L 12 01 2018 3 1 12 CCS Overview menu groups ...

Page 121: ... group à p 3 29 Set display brightness and date time menu Switch units menu Lamp test 3 information menu group à p 3 31 Operating hours menu Engine transmission error menu Crane operation error menu 4 Various controls menu group à p 3 36 Outrigger lighting on off Reverse camera on off1 5 Emergency operations menu group à p 3 37 Switching emergency operation on off Switching towing mode on off 1 Ad...

Page 122: ...g elements for driving 3 1 Overview of the operating elements 3 26 3 302 709 en Operating manual GMK5150L 12 01 2018 3 1 13 Carrier menu group 1 Suspension level adjustment menu à p 3 27 2 Driving menu à p 3 28 ...

Page 123: ...3 68 2 Level adjustment system enabled display à p 3 68 3 Suspension operation pressure gauge à p 3 64 4 Left level pre selection à p 3 68 5 Overall level pre selection à p 3 68 6 Right level pre selection à p 3 68 7 Display of current inclination à p 3 69 8 Rear level pre selection à p 3 68 9 Setting the on road level à p 3 69 10 Vehicle level display à p 3 69 11 Suspension on off à p 3 64 ...

Page 124: ... 3 Longitudinal differential lock display Longitudinal differential lock on off à p 3 57 à p 3 57 4 Steering mode display à p 3 62 5 Steering system malfunction warning à p 3 62 6 Normal steering mode on road driving on off à p 3 62 7 Manual separate steering on off à p 3 63 8 Separate steering for driving around corners on off à p 3 62 9 Separate steering crab travel mode on off à p 3 63 10 Trans...

Page 125: ...ing 3 1 Overview of the operating elements Operating manual 3 302 709 en 3 29 GMK5150L 12 01 2018 3 1 14 Settings menu group s 1 Set display brightness and date time menu à p 3 30 2 Switch units menu à p 3 31 3 Lamp test à p 4 10 ...

Page 126: ...isplay brightness and date time menu 1 Selection setting the display brightness à p 4 11 2 Increasing reducing the value à p 4 11 3 Display in percentage à p 4 11 4 Display brightness à p 4 11 5 Adjust time selection à p 5 23 6 Setting the time à p 5 23 7 Increasing reducing the value à p 5 23 8 Switching the display type à p 5 23 ...

Page 127: ...1 Overview of the operating elements Operating manual 3 302 709 en 3 31 GMK5150L 12 01 2018 Switch units menu 1 Display units in Metres Degrees Celsius Kilograms Bar à p 5 64 2 Display units in Feet Degrees Fahrenheit lbs Psi à p 5 64 ...

Page 128: ...ving 3 1 Overview of the operating elements 3 32 3 302 709 en Operating manual GMK5150L 12 01 2018 3 1 15 Menu group Information 1 Operating hours menu à p 3 33 2 Engine error menu à p 3 34 3 Crane operation error menu à p 3 35 ...

Page 129: ...ng 3 1 Overview of the operating elements Operating manual 3 302 709 en 3 33 GMK5150L 12 01 2018 Operating hours menu s 1 Keycode input à p 5 24 2 Carrier à p 5 24 3 Engine à p 5 24 4 Transmission à p 5 24 5 Selection all à p 5 24 ...

Page 130: ... operating elements 3 34 3 302 709 en Operating manual GMK5150L 12 01 2018 Engine transmis sion error menu 1 Display of error total errors à p 8 17 2 Engine symbol display 3 Transmission symbol display 4 Error code display 5 Previous error 6 Next error ...

Page 131: ...g 3 1 Overview of the operating elements Operating manual 3 302 709 en 3 35 GMK5150L 12 01 2018 Crane operation error menu 1 Current errors total errors display à p 8 17 2 Error code 3 Deleting errors 4 Next error 5 Previous error ...

Page 132: ...ents for driving 3 1 Overview of the operating elements 3 36 3 302 709 en Operating manual GMK5150L 12 01 2018 3 1 16 Various controls menu group 1 Outrigger lighting on off à p 3 67 2 Reverse camera on off à p 3 52 ...

Page 133: ...elements Operating manual 3 302 709 en 3 37 GMK5150L 12 01 2018 3 1 17 Emergency operations menu group 1 Switching emergency operation on off à p 14 65 2 Switching towing mode on off Transfer case for off road gear on off à p 8 31 3 Transfer case display à p 8 31 ...

Page 134: ...s for driving 3 1 Overview of the operating elements 3 38 3 302 709 en Operating manual GMK5150L 12 01 2018 3 1 18 Outrigger control units Contain operating elements for crane operation à Outriggers control units p 9 85 ...

Page 135: ... elements to be active If some operating elements do not work first read the following chapters which are referred to at the respective places before contacting Manitowoc Crane Care G Risk of accident by operator 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 ...

Page 136: ...ections always depend on whether the carrier or the superstructure is being operated On the carrier The driver s cab is always at the front which means that Forwards always means with driver s cab leading Backwards always means the rear lights on the carrier are to the front On the superstructure The main boom head is always at the front which means that 1 front 2 right 3 rear 4 left 1 front 2 rig...

Page 137: ...ng symbol has been selected with the direction buttons 1 A selected menu is marked in colour and can be opened In these operating instructions we always refer to colours in terms of The symbol is red for instance regardless of whether the background 1 of a symbol is red or whether only parts 2 of a symbol are red This applies to all symbols and all colours If the instruction given in this section ...

Page 138: ...ling speed The truck crane must be stationary 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 p 4 9 Lock unlock steering col umn à p 5 15 1 Select the Engine speed menu 2 Reduces the idling speed 3 Increase idling speed 4 Idling speed sett...

Page 139: ...uck crane must be driving at a speed at least 15 km h 9 mph Instrument panel Tachometer 2 Select the Cruise control menu symbol 1 is grey 3 Switches on or increases the speed symbol 1 is white 4 Switches on or reduces the speed 5 switch off à p 5 38 1 Select Temposet symbol 2 is grey 3 Switches on or increases the speed limit symbol 2 is white 4 Switch off or reduce the speed limit 5 Switch Tempos...

Page 140: ...t On AdBlue system malfunction Flashing Adblue tank empty or fault à p 5 45 Out Torque reduction off On Torque reduction on Flashing Reduction in torque on the next time the engine is started à p 5 45 Press upwards once Torque reduction overridden for 30 minutes after 30 minutes Press up again Torque reduction overridden for 30 minutes after 30 minutes Press up again Torque reduction overridden fo...

Page 141: ... 302 709 en 3 45 GMK5150L 12 01 2018 CCS display Adblue filling level indicator 3 2 5 Battery master switch Display Green Over 10 over 4 l 0 9 gal Yellow 5 to 10 2 to 4 l 0 4 to 0 9 gal Red Below 5 less than 2 l 0 4 gal à p 4 7 Switch on Push up Switch off unlock and then press in downwards à p 4 9 ...

Page 142: ...V 24 V Only connect electrical devices with the matching specification to the sockets Reading lamp 12 V As additional equipment the truck crane is equipped with a reading lamp If necessary plug the 12 V reading lamp into the 12 V socket Press the button 1 lamp on off Switch on Press in switch 1 at the top Switch off Press in switch 1 at the bottom 1 Socket 24 V max 15 A 2 Socket 12 V max 15 A ...

Page 143: ... the CCS control panel the overview of the menu groups 2 appears A symbol is selected with the arrow buttons in order to call up a menu The selected symbol is shown in red The OK button on the control panel is pressed in order to open a menu Menu control Buttons for selecting activating and confirming areas on the CCS display Select Activate confirm The function of the buttons is different dependi...

Page 144: ...ess p 4 11 Display temperature warning display The temperature of the control unit is measured by an internal sensor 1 Press The opened menu closes the menu from the next higher level is opened Input mode is deactivated 1 Press After the first press Menu groups overview display After a subsequent press Next previous group overview Blue flashing Temperature too low display will not be switched on T...

Page 145: ... A symbol is selected such as symbol 2 Deselect A favourites symbol is selected 3 2 8 Transmission à Operating the transmission p 5 25 Transmission control unit Selecting the transmission mode The engine must be running s 1 Press The symbol is marked as a favourite 1 Press The favourites selection is cancelled Position N Select neutral No gear engaged Position D When at a standstill Select forward...

Page 146: ...ards Select neutral The truck crane may be stationary or driving Press in once Change over between automatic and manual operating mode without change of gear à p 5 29 The truck crane must be stationary Push forwards once Shift up starting gear 1 gear Push to the rear once Shift down starting gear 1 gear If the truck crane is in motion Push forwards once Upshift 1 gear Manual operating mode on Push...

Page 147: ...iving mode Transmission display Error messages display 1 Currently engaged gear forwards 1 to 16 for example 6 2 Neutral position switched on 3 Gear currently engaged 1st reverse gear 4 Gear currently engaged 2nd reverse gear 5 Automatic operating mode 6 Manual operating mode 1 Clutch heavily loaded 2 Clutch malfunction 3 Gear shift malfunction ...

Page 148: ...e reverse camera 1 displays the area behind the truck crane on the CCS display in the driver s cab Switching on Automatically when reversing 1 Manual select symbol 3 and confirm The display 5 shows the area behind the truck crane Switching off Automatically when driving forwards or in neutral position 4 Manual press button 6 The display 2 shows the CCS menu ...

Page 149: ...ty lies with the crane operator Manitowoc Crane Group Germany GmbH explicitly states that no liability is accepted for damage resulting from a failure to observe these instructions The BirdView system 270 shows rear and side views next to the carrier in the driver s cab All cameras 2 simultaneous show images on the monitor 1 The monitor 1 shows the area 3 to the rear and side of the carrier s S Ri...

Page 150: ...e cameras must not be removed or misadjusted If a camera is mounted on the storage box then the storage box must not be removed H There may be no spare wheel installed on the rear of carrier Switching on Switch on the ignition the monitor shows the area around the truck crane Switching off Switch off the ignition the monitor switches off ...

Page 151: ...e for off road gear on off Transfer case display The current status is shown using different symbols Transfer case for off road gear on off Switching towing mode on off à p 8 31 Opening Select symbol 1 and confirm menu is opened Switch on Select symbol 2 and confirm off road gear engaged Switch off Select symbol 1 and confirm off road gear disengaged 1 Off road gear on 2 Off road gear off on road ...

Page 152: ...Operating elements for driving 3 2 Short description of the operating elements 3 56 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 153: ...al lock on off For drive 10 x 8 x 10 simultaneously drive of first axle line on out A longitudinal differential lock display B transverse differential lock display The current status is shown using different symbols Opening Select symbol 1 and confirm menu is opened Switch on Select symbol 1 and confirm symbol is red Switch off Select symbol 1 and confirm symbol is green Switch on Select symbol 1 ...

Page 154: ...kes Engine retarder transmission retarder à Additional brakes p 5 43 Multipurpose switch The braking effect is the least in position 1 and the greatest in position 5 1 Current supply pressure in brake circuit 1 2 Current supply pressure in brake circuit 2 3 Red supply pressure insufficient White supply pressure sufficient à p 5 60 0 Forward Engine retarder and transmission retarder off 1 Back 20 b...

Page 155: ... To engage the parking brake Pull the lever down until it locks into place 2 To release the parking brake Lift the lever and push it up until it latches into place 3 Operating as auxiliary brake Shift the lever to intermediate position The braking force is increased continuously by moving the lever from top to bottom 4 Test position for towing a trailer Push the lever backwards and downwards until...

Page 156: ...e off ignition on or Engine on fault stop check oil loss Out Engine on no fault à p 8 6 On approx 10 km h 6 mph not reached or Steering malfunction stop and check for oil loss Out Emergency steering pump ready to function à p 8 6 1 After switching on the ignition Lit goes out after about three seconds if there is no error Whilst driving Lit 1 x warning buzzer and goes out again continued driving p...

Page 157: ...lines are steered with the steering wheel Press and hold button 1 s 1 After switching on the ignition Lit goes out after about three seconds if there is no error Whilst driving Lit symbol 2 red Steering system faulty 3 and or 4th axle is no longer steerable Stopping while taking the traffic situation into account Repair required à p 8 7 To the left 3 and 5th axle lines turn to the left To the righ...

Page 158: ...2 seconds otherwise the steering mode remains unchanged Normal steering mode on road driving on off Separate steering for driving around corners on off 1 Yellow Steering system malfunction lamp 3 lit Red Steering system warning lamp 2 lit No symbol No malfunction warning à p 8 7 2 Orange Steering mode switched on indicator Blue Automatic alignment of the steering angle is active Switch on Select s...

Page 159: ...ring is switched on the speed is limited Current wheel position display The current status is shown using different symbols Switch on Select symbol 1 and confirm Symbol 2 is displayed Switch off Select a different steering mode Symbol 3 à p 5 60 Switch on Select symbol 1 and confirm Symbol 2 is displayed Switch off Select a different steering mode Symbol 3 à p 5 60 1 Straight ahead 2 Driving aroun...

Page 160: ...on Select symbol 1 and confirm Symbol 2 green on road driving Suspension on enabled for on road driving Switch off Select symbol 1 and confirm Symbol 2 red Suspension off blocked for crane operation à p 5 16 1 Suspension pressure 1st and 2nd axle lines left hand side 2 Suspension pressure 1st and 2nd axle lines right hand side 3 Suspension pressure 3rd and 5th axle lines left hand side 4 Suspensio...

Page 161: ...nstrument panel Checking headlight full beam s 1 Parking light headlight Middle position 2 Flash the headlights Upwards The parking light headlight must be switched on 3 Headlight full beam Down latches into place 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 Interval fast Continuous...

Page 162: ... Out Turn signal indicator off or turn signal indicator on and filament lamp faulty 1 Flashing Turn signal indicator on and trailer electrically connected Flashes once Turn signal indicator on and trailer not electrically connected Out Turn signal indicator off Switch on Press downwards light in the switch flashes Switch off Press in above gone out 1 Light off 2 Parking light on Instrument lightin...

Page 163: ...ight Rotating beacon on off CCS display Outrigger lighting on off Roof The lamps on the driver s and passenger s side are identical Cab lighting On Headlight on Out Headlight off Switch on Push up Switch off Push down Switch on Select and confirm symbol 2 Switch off Select and confirm symbol 1 1 On 2 On off via door contact 3 Off 4 Reading lamp on ...

Page 164: ...lect and confirm the corresponding symbol Level adjustment system enabled display Level change Movement stops after the button is released and when an end position is reached Opening Select symbol 1 and confirm menu is opened 2 Left level pre selection 1 Front level pre selection 4 Right level pre selection 5 Rear level pre selection 3 Overall level pre selection 1 Displayed Level pre selection on...

Page 165: ...is switched on Display of current inclination Switching between measuring ranges 1 On road level 2 Off road level 3 Error 4 Operation pressure in the suspension struts à p 5 53 1 Select and confirm level is changed until the on road level is reached 2 On road driving level reached à p 5 54 1 Directional indicator 2 Inclination indicator 3 Measuring range display à p 5 56 The current measuring rang...

Page 166: ...ometre counter The ignition must be switched on 1 Open the time menu Press the button the time correction menu opens 2 Time correction Press the button the time is increased 3 Time correction Press the button the time is decreased 1 Time correction Press the button the time is increased 2 Time correction Press the button the time is decreased 1 Indicates the speed in km h 2 Indicates the speed in ...

Page 167: ...staff from the engine manufacturer transmission manufacturer or by Manitowoc Crane Care The following connections are below the cover 4 3 2 20 Push up roof Opening Hold the push up roof 1 by the handles 2 and push up into the required position Closing Hold the push up roof by the handles 2 and pull down until it latches into place 1 Carrier electronics diagnostics 2 Transmission diagnostics 3 Engi...

Page 168: ...omputer On the steering wheel Main menu display 1 Previous menu window menu entry upwards 2 Next main menu select next entry increase or reset value 3 Next menu window one menu entry downwards 4 Previous main menu select previous entry reduce value 5 Open and close data entry window acknowledge messages 6 Save display menu window 1 Tour data 2 Driving 3 Audio and communication 4 Operation and main...

Page 169: ...a menu 3 2 22 Front flap Opening Fold up the front flap 1 Fasten the support 2 in the clamp 3 Closing Lift the front flap 1 Fasten the support 2 in the clamp 4 Fold down the front flap Press the front flap against the driver s cab on both sides until you can hear it latch into place 1 Total mileage 2 Daily mileage 3 Time 4 Outside temperature ...

Page 170: ...and when an end position is reached Jog function Press button 1 briefly the window opens all the way to the end position Press button 2 briefly the window closes all the way to the end position G Risk of crushing when closing the windows If the window winders encounter resistance they do not stop but keep on moving at reduced power A Window winder driver s door B Window winder passenger door 1 To ...

Page 171: ...ver s and passenger s door H Always take the ignition key with you before closing the door from outside with the handle pressed in 2 Once closed in this manner the door can only be opened again using the ignition key Locking Turn the key towards B or Press in the handle 2 Unlocking Turn the key towards A or Pull the handle 2 Opening Pull the handle 1 or Pull the handle 2 ...

Page 172: ...Operating elements for driving 3 2 Short description of the operating elements 3 76 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 173: ...oor is open you can reach the handle 1 The handle 2 is located on the outside of the crane cab Swing out ladders Folding out Release the spring latch 1 Swing the ladder 2 outwards and fold downwards locking bar 3 engages If need be engage the spring latch 5 and pull out another access ladder 4 s G Hazard due to unsecured ladders Always secure the ladders before driving The prevents the ladders fal...

Page 174: ...arrier Secure the ladder 2 with the spring latch 1 Folding ladder shelf on the rear of carrier For the use Ladder 5 to erect and fold out Taking off the clamp 3 and taking out the ladder Plug the clamp 3 into the mounting at the carrier Push the clamp to the front and secure it with the locking bar 4 For driving crane operation Fold together the ladder 5 and push under the clamp 1 Plug the clamp 3...

Page 175: ...Ladder 1 to erect and fold out Hold the clamp 2 and open the lock 3 Fold down the clamp 2 Take out the ladder Fold the clamp 2 upwards until it engages For driving crane operation Fold together the ladder 1 Place the ladder in the centre of the clamp 2 Push the ladder back so that the holder 5 engages on a rung 4 Fold the clamp 2 upwards until it engages Always secure the holder 2 before driving e...

Page 176: ...Operating elements for driving 3 2 Short description of the operating elements 3 80 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 177: ...river s cab You can also start the engine from the outrigger control units à p 12 27 4 1 1 CHECKLIST Starting the engine H This checklist is not a complete operating manual There are accompanying operating instructions which are indicated by cross references Observe the warnings and safety instructions specified here 1 Check that the valves on the hydraulic tank are open à p 4 8 2 Check the coolan...

Page 178: ...itch on the battery master switch à p 4 9 5 Check that all emergency stop switches have been reset à p 4 19 6 Check the oil level in the engine and gearbox à Maintenance manual 7 Check that the parking brake is engaged 8 Switch on the ignition and check the instruments and displays à p 4 9 9 Adjust the brightness of the CCS display if necessary à p 4 11 ...

Page 179: ...0L 12 01 2018 10 Check the fluid supply à Fuel tank p 4 5 à AdBlue tank p 4 7 à Fuel tank auxiliary heater p 11 5 11 Shift the transmission to neutral à p 5 26 12 Start the engine à p 4 13 13 Conduct the necessary checks after starting the engine à p 4 15 14 In the event of low outside temperatures à CHECKLIST At low temperatures p 4 4 ...

Page 180: ...hen operating the truck crane in low outside temperatures 1 The fuel and engine oil must be suitable for use at the respective outside temperature à Separate engine operating instructions provided by the manufacturer 2 The engine coolant must contain sufficient antifreeze à Separate engine operating instructions provided by the manufacturer 3 The windscreen washing system must contain sufficient a...

Page 181: ...ent space for the fuel to expand Close both tanks with the caps after refuelling Also fill the tank for the crane operator s cab heating system à Fuel tank auxiliary heater p 11 5 s G Danger of fire due to flammable gases Switch off the engine the heater and all additional heaters before refuelling G Risk of accidents if the tank is not closed Close the tank each time you have refilled it In this ...

Page 182: ...el for driving operation display 2 The fuel tank 4 is filled with the fuel for crane operation display 3 When refuelling open filler necks 1 or 4 Fill with the correct fuel in good time and close the tank correctly Leave sufficient space for the fuel to expand Close both tanks with the caps Switching over the fuel supply When fitted with dual tanks the fuel supply is automatically switched over de...

Page 183: ...he tank each time you have refilled it In this way you can prevent other vehicles from being endangered by the cap falling off or consumables escaping S Risk of damage to the engine and catalytic converter Unauthorised consumables can damage the engine and catalytic converter and void the warranty Only use consumables approved by the engine manufacturer G Risk of injury from ammonia vapours Ammoni...

Page 184: ... the truck crane may only be driven with AdBlue Driving without AdBlue will invalidate the truck crane s licence for use on public roads and you are no longer permitted to drive on public roads 4 1 4 Checks before starting the engine At the hydraulic tank Before you start the engine all valves on the hydraulic tank must be open Check that the valves are open lever 1 parallel to the line Open all t...

Page 185: ...battery master switch will be switched on Checking the hand held control Check that the hand held control has been removed and that the bridging plugs for the hand held control are inserted into all sockets à p 9 83 4 1 5 Switch the ignition on Insert the ignition key into the ignition lock and turn the key to position 2 After switching on the ignition a lamp test is performed and switching states...

Page 186: ...ching states of the differential locks and the steering are compared Differential locks The state last saved is retrieved In the Driving menu the corresponding sym bols 1 are shown and the electronics system triggers the switching operations Steering When you switch the ignition on the steering is always set to On road driving 2 irrespective of what setting was last saved S Risk of accident from f...

Page 187: ...and keep them clean to avoid contamination that can affect the brightness adjustment Setting the minimum brightness H The brightness of the headlight is reduced to 40 regardless of the mini mum brightness setting but can be increased again manually at any time Open the Set display brightness and date time menu 1 Select and confirm the symbol 1 Set the desired brightness on the display 2 Confirm th...

Page 188: ... for driving switching it off 4 1 Starting the engine from the driver s cab 4 12 3 302 709 en Operating manual GMK5150L 12 01 2018 You can cancel the entry at any time using the 1 or 2 buttons The settings are then reset ...

Page 189: ...n also start the engine from the outrigger control units à p 12 27 Refer to the separate operating manual provided by the engine manufac turer for operating the engine The engine can only be started if The bridging plugs have been inserted in all sockets of the carrier and superstructure for the hand held control à p 9 83 The lamp 1 has gone out superstructure ignition off The parking brake must b...

Page 190: ...g again If the engine does not start after several attempts à Malfunctions on the engine p 8 19 S Danger of explosion when using starter fuel The engine may never be started with the aid of starter fuel The starter fuel sprayed into the intake manifold can ignite S Risk of malfunctions in the carrier electronics Always wait until the start menu is displayed before starting the engine This prevents...

Page 191: ...ing and malfunction messages on the on board computer display p 8 9 If a red symbol lights up or if a message demands it switch the engine off immediately Also check the following displays The colour of the bar under the value indicates the range within which the value lies s S Risk of damage to the engine Observe the symbols and messages in the display area of the main menu and in the on board co...

Page 192: ...anel After the engine start several lamps must go out The lamp 3 only goes out when the vehicle starts moving Check that the lamps 1 and 2 go out If one or more lamps light up à Warning or malfunction messages on the instrument panel p 8 5 If the Steering system warning 1 red lamp does not go off then you must perform the required checks before you start off à p 8 5 G Risk of accidents because the...

Page 193: ... when the truck crane is stationary Increasing reducing the idling speed Press the button 1 repeatedly until Engine speed is shown in the on board computer display Increase or decrease the speed stepwise using the buttons 2 or 3 The engine speed is increased reduced by 20 rpm After about 3 seconds the setting is automatically saved Switching off the idling speed change Press the button 1 repeatedl...

Page 194: ...other one or two minutes at increased idling speed Ignition lock Turn the ignition key to position 0 the engine will stop Outrigger control units Press the button 1 the engine will switch off After switching off If you want to park the truck crane à p 5 46 G 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 r...

Page 195: ...r is present this is then triggered H Do not operate the emergency stop switch to switch the engine off in nor mal operation Only operate the emergency stop switch in an emergency situation Resetting the emergency stop switch You can restart the engine only after you have reset the emergency stop switch Switch off the ignition Turn the actuated emergency stop switch until it disengages again If ai...

Page 196: ... engine speed is exceeded In this case the symbol 1 will turn red in the start menu display area à p 8 13 The symbol stays red until the ignition has been switched off The engine can be restarted only after the flap has been opened Opening the air intake inhibitor The following requirements must be met in order to open the air intake inhibitor The ignition must be switched off The emergency stop s...

Page 197: ... 6 1 à p 12 71 The main boom must be telescoped for driving operation à p 11 110 All telescopic sections must be locked together The slewing gear is switched off à p 11 120 The boom must be resting in the boom rest à p 5 9 2 When the main boom is resting on a dolly All telescopic sections must be locked together The slewing gear is switched off à p 11 120 The boom floating position must be switche...

Page 198: ...ion are folded in removed à p 12 150 All spotlights are switched off and swivelled if possible in such a way that no other drivers will be blinded by reflection à p 11 130 The lighting of the outrigger is switched off à p 3 36 5 Anemometer air traffic control light and camera system must be removed à Anemometer and air traffic control light p 12 145 à Camera on main boom p 12 152 6 The camera on t...

Page 199: ... Check the level and function of the windscreen washing system à Maintenance manual 11 Carry out an inspection of the truck crane looking out in particular for any leaks of fluids oil fuel or water 12 The warning signs for marking the vehicle width are folded down only for vehicle widths of over 2 75 m 9 0 ft Vehicle width à p 1 8 Warning signs à p 5 9 13 If necessary check whether the third brake...

Page 200: ...axle loads lengths widths height etc For a driving mode with a maximum axle load of 12 t 26 500 lbs à Driving modes p 6 1 15 The fold up berth must be folded up and secured à p 5 48 16 All additional parts which may be transported must be secured against falling down 17 Carry out all activities and inspections required for starting the engine à CHECKLIST Starting the engine p 4 1 18 Switch on igni...

Page 201: ...50L 12 01 2018 20 Adjust the steering column à p 5 15 21 Adjust the mirrors à p 5 7 22 Set the tachograph insert the diagram sheet à p 5 18 23 Start the engine and carry out all checks à Checks after starting the engine p 4 15 24 Check the electrical system à p 5 7 s ...

Page 202: ... à p 5 10 27 Check that all switching states for on road driving are set and that the corresponding symbols are shown Suspension switched on à p 5 17 Longitudinal and transverse differential locks switched off à p 5 51 Separate steering switched off the symbol for on road driving is displayed à p 5 63 On road level is set à p 5 54 Establish the switching states for on road driving if necessary ...

Page 203: ...ired Parking light headlight rotating beacons fog tail light side marker lights Hazard warning system Brake lights Reversing lamp buzzer Headlight full beam Turn signal indicator Windscreen wipers Windscreen washing system Horn Adjusting the 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 o...

Page 204: ...adjustment Turn the button to position Press the button 5 the mirror moves Mirror heating A Neutral position B Mirror on the driver s side or C Mirror on the passenger side 1 Up 2 Right 3 Down 4 Left 1 Switch on Press button once lamp 3 turns on 2 Switch off Press button once lamp 3 turns off ...

Page 205: ...locking bar 2 Checking the vehicle height The vehicle height given at on road driving level is only maintained when the main boom is resting in the boom rest à p 1 8 If the Vehicle height check function is present the position of the main boom in the boom rest is monitored In this case a corresponding warning is shown on the CCS display if the main boom has not been correctly put down à p 8 16 s S...

Page 206: ...g brake is applied Allow the engine to run The supply pressure builds up and you can speed up this process by pressing the accelerator The light 1 turns off once the supply pressure reaches about 5 5 bar 80 psi Refill the supply pressure until about 8 bar 116 psi is reached and a valve audibly discharges pressure There is now sufficient supply pressure G Risk of accidents by truck crane moving uni...

Page 207: ...vice brake Release the parking brake When the supply pressure is sufficient the parking brake is released and the lamp 1 goes out s G Risk of accidents by truck crane moving unintentionally Always apply the service brake before releasing the parking brake This prevents the truck crane rolling in an uncontrolled manner when the parking brake is released ...

Page 208: ... connected to the socket 3 For versions without storage box For on road driving the brake light 2 must be connected to the socket 3 The plug of the brake light 1 must be inserted in the dummy socket 4 S Risk of damage to the connecting cables Always check before driving whether the plugs are plugged into the required sockets and always disconnect the connection cables before disassembling the stor...

Page 209: ...d in sufficient air pressure is available in the secondary consumer circuit You may have to build up the supply pressure à p 5 10 Sit on the driver s seat the seat will rise to the last position set You can make adjustments to suit your body size and shape Settings for body size s 1 Back rest angle 2 Seat heating on off1 3 Lower it to the lowest position 4 Seat height 5 Seat inclination 6 Spring h...

Page 210: ... settings are made pneumatically The following applies to all buttons Adjusting the passenger seat The passenger s seat is adjusted mechanically 1 Lower lumbar area support 2 Upper lumbar area support 3 Lateral support Empty the air cushion Press Fill the air cushion Press 1 Seat inclination 2 Back rest angle ...

Page 211: ... consumer circuit à Building up supply pressure p 5 10 Push the 1 button down once The steering column is unlocked for about 6 seconds Move the steering column into the desired position Push the button 1 up once Or wait until the steering column locks automatically after about 6 seconds G Risk of accidents by unlocked steering column Always stop the truck crane before you unlock the steering colum...

Page 212: ...urrent switching state of the suspension is shown on the display 1 in all the menus To switch the suspension on and off you must open the Suspension level adjustment menu Open menu You can open the menu only when the truck crane is stationary or when the current speed is below approx 5 km h 3 mph Open the Suspension level adjustment 1 menu Symbol green Suspension is switched on Symbol red Suspensi...

Page 213: ...ed off the suspension cylinders are locked This state is intended only for crane operation Select and confirm the symbol 1 When the suspension is switched off the symbol 2 is red G 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 If the rigged truck crane was standin...

Page 214: ...erating manual There you will find detailed information marking the diagram sheets malfunctions etc Prerequisites To set the tachograph the following requirements must be met The ignition is switched on The truck crane is stationary No error message is displayed In the event of malfunctions Check that a malfunction has occurred If a malfunction has occurred the tachograph display 1 will show an er...

Page 215: ...ar as it will go The diagram sheet mounting 2 and an isolat ing plate 1 are in the drawer Checking the time setting First check the time setting for the diagram sheet mounting 2 fold the isolating plate 1 upwards to do this Insert a diagram sheet Make sure that the diagram sheet is under the spring 4 Check whether the diagram sheet s time scale on the marking 3 is showing the current time Correcti...

Page 216: ...e insert the diagram sheet 2 Fold the isolating plate downwards Put the diagram sheet 1 for driver 1 on the isolating plate Take care that the diagram sheet is under the holder 3 Push the drawer 2 back in until it engages For single driver operation the diagram sheet mounting under the isolating plate is empty and only the diagram sheet 1 for driver 1 is inserted S Risk of malfunctions in the elec...

Page 217: ...me 5 Driver 1 time group 1 1 Driver 1 diagram sheet inserted 1 2 Total kilometres of the truck crane 3 Driver 2 time group 2 1 Driver 2 diagram sheet inserted 2 2 Setting the time groups Set the time group for driver 1 using the button 1 The set time group is shown with the symbol 1 1 Set the time group for driver 2 using the button 2 The set time group is shown with the symbol 2 1 s ...

Page 218: ...nd by time When setting the working hours and stand by time observe the applicable local regulations for the country in which you are working Stand by time Periods of presence at the truck crane e g crane operation maintenance work passenger time etc Breaks and periods of rest These times are prescribed by law and must be observed H If the drivers swap during two driver operation the diagram sheet...

Page 219: ...onfirm the symbol 2 Select the current time expressed as a deviation from UTC time Confirm the selection The newly set time is shown on the display 6 Switching the display type Select and confirm the display 3 Select the symbol for the desired display type Confirm the selection the selected display type becomes orange You can cancel the input at any time Press button 1 no values are changed 4 24 h...

Page 220: ...cannot be deleted Open the Operating hours 1 menu Displays The operating hours are recorded as follows The value 1 indicates the total operating hours for example 1 680 hours The value 2 shows the operating hours which can be reset Reset The displayed operating hours 3 can be reset Select and confirm the symbols 1 one after the other Confirm the entry with the symbol 2 You can individually select ...

Page 221: ...nges However gears can be changed manually at any time 5 2 1 Switching on When the ignition is switched off the transmission must always be in the neutral position N Shift to position N If you switch on the ignition in positions D or R malfunctions may occur Switch on the ignition The electronic transmission system is switched on and a warning buzzer sounds for several seconds ...

Page 222: ...tch the transmission to neutral position while driving the drive line will be interrupted As a result you will no longer be able to accelerate the truck crane for instance when trying to avoid an obstacle and the engine retarder will have no effect G Risk of accidents due to the truck crane rolling away Always apply the parking brake or the service brake before you switch to the neutral position T...

Page 223: ...esponding message is also displayed If necessary wait until the supply pressure has built up and the message disappears à Building up supply pressure p 5 10 Release the accelerator In order to drive forwards shift to position D drive backwards shift to position R An acoustic signal is given with additional equipment The operating mode Automatic is now selected An appropriate starting gear is selec...

Page 224: ...gear that is automatically selected on starting H Only change the gear selected on starting if it is absolutely necessary to do so Starting is a gear that is too high causes premature clutch wear Pull the gearshift lever upwards once The starting gear is shifted up by one gear Press the gearshift lever downwards once The starting gear is shifted down by one gear The altered starting gear is shown ...

Page 225: ...switches to the Automatic operating mode When at a standstill a suitable starting gear is engaged While driving the gears are changed automatically depending on the load Change to manual mode The Manual operating mode is intended for off road driving with load conditions changing at short notice You can change over either with a gear change or without a gear change Changing over without gear chang...

Page 226: ...t off the accelerator and apply the service brake Switch to the neutral position N and leave the engine running until the clutch has cooled down and the symbol 1 is no longer shown on the display Select a lower starting gear Start to move again G Risk posed by unexpected rolling Also apply the parking brake before starting on sloping ground The gear will be engaged only once you depress the accele...

Page 227: ...own the transmission first shifts to a lower gear After that it will shift to a higher gear only once a higher engine speed has been reached so as to achieve maximum accel eration If you execute a manual gear change using the gearshift lever you simulta neously switch to Manual operating mode The transmission will only perform an automatic shift after you have switched to Automatic operating mode ...

Page 228: ...ift lever downwards briefly The newly engaged gear will be shown in the display H If you initiate a gear change which would cause the maximum permitted engine speed to be exceeded the transmission does not shift In that case slow the truck crane down until a permissible engine speed is reached and downshift again Upshifting one gear Push up once Upshifting two gears Briefly push upwards twice Upsh...

Page 229: ... km h you can pre select a reverse gear or for ward gear when driving The gear is switched when the truck crane comes to a stop The shifting operation is complete when the display shows the selected gear 5 2 8 Stopping In order to stop remove your foot from the accelerator and actuate the brake pedal The transmission declutches shortly before the vehicle comes to a halt The current gear remains en...

Page 230: ...ture is between 20 C and 25 C 4 F and 13 F the gear oil must be preheated before you start driving the truck crane Let the engine run at idling speed for at least 10 minutes before you start driving G Danger of unexpected moving off rollers Always shift to the neutral position on the roller type dynamometer In position D or R a suitable gear is engaged for the speed The engine braking power is app...

Page 231: ...orresponding ABS system is faulty and the wheels will no longer be prevented from blocking The full braking force remains intact à Malfunctions of the service brake p 8 25 If the lamp 1 lights up then the braking process is supported by the ABS system s G 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 mo...

Page 232: ...p 2 is lit symbol 1 red Steering system warning Stop as quickly as possible and perform the required checks à p 8 7 Warning messages Observe all error and warning messages Note the warning messages at the CCS display 1 à p 8 13 Note the warning messages at the On board computer display 2 à p 8 13 S Risk of accident due to mobile crane that cannot be steered and leaking oil If a warning message occ...

Page 233: ... be sucked in and the fuel system must then be bled à Maintenance manual Adblue filling level indicator If possible never run the Adblue tank completely dry refuel in due time à p 4 7 If the Adblue tank is empty the lamp 1 lights and the slewing moment is reduced à p 5 45 Coolant temperature display 1 Green Economic consumption 2 Yellow Engine brake active 3 Red Engine speed too high danger à Chec...

Page 234: ...he accelerator After the accelerator is released cruise control reverts to the set speed H On downhill slopes the speed set may be exceeded since cruise control does not brake the truck crane Switch the cruise control off on downhill slopes Increasing reducing the speed Increase with 1 Reduce with 2 Press the corresponding button until the desired speed is reached or Press the corresponding button...

Page 235: ...hing off Press the button 1 once The cruise control is now switched off The symbol 2 goes out in the Driving display Cruise control is also switched off when the service brake or additional brake is applied when speed falls below 10 km h 6 mph when the Temposet function is switched on when the ignition is switched off ...

Page 236: ... Driving display The current speed is taken as the maximum speed You can exceed the speed by pressing the accelerator as far down as it will go kick down The Temposet limits the speed again only once you release the accelerator and press it again Increasing reducing the maximum speed Increase with 1 Reduce with 2 Press the corresponding button until the desired speed is reached or Press the corres...

Page 237: ...eversing you must do the following Shift into position R Apply the parking brake Press the accelerator Release the parking brake after the clutch has engaged If the symbol 1 with a message is shown when starting Shift to a lower gear or End the starting operation s G Risk of accidents when driving in neutral position Never switch into neutral position whilst driving In neutral position the truck c...

Page 238: ...5 43 Downshifting To increase the braking force of the engine you can select a lower gear Press the gearshift lever downwards once Manual operating mode is switched on and if possible one gear is shifted down If you initiate a gear change which would cause the maximum permitted engine speed to be exceeded the transmission does not shift In that case slow the truck crane down until a permissible en...

Page 239: ...wer H For long downhill stretches we recommend that you use level 2 When the transmission retarder is switched on you cannot regulate the speed with the accelerator Switching on the additional brakes Pull the switch back to the required level latch into place briefly at each level Switching off the additional brakes Press the switch upwards to level 0 When the additional brake is switched on the l...

Page 240: ...versing you must do the following Shift into position R Release the parking and service brakes Apply the accelerator if you wish to accelerate Do not apply the accelerator if you wish to brake with the engine Driving On certain gradients the transmission may switch continuously back and forth between two gears In this event either release the accelerator slightly or downshift by one gear G Danger ...

Page 241: ... can override torque reduction up to 3 times If the level in the AdBlue tank falls to the reserve level then the symbol 1 is displayed Immediately fill up with AdBlue à AdBlue tank p 4 7 If the AdBlue tank is empty the light 1 will flash The engine torque is reduced the next time the engine is started The engine torque is reduced Push the button 1 upwards to override the torque reduction You can o...

Page 242: ...rier Push the chock 2 behind the bracket 3 and hang it on the holder 1 A Folding out Push the latch 4 through the hole 5 The chock unfolds by spring force B Folding up Push the chock together until the latch 4 engages in the hole 5 1 Stop the truck crane 2 Apply the parking brake 3 Switch to neutral position à p 5 26 4 Turn off the engine à p 4 18 G Risk of accidents by truck crane moving unintent...

Page 243: ...ine has been switched off Slide the guard 1 downwards and push the switch underneath it 2 in the battery master switch is now off Securing the truck crane against unauthorised use Secure the truck crane against unauthorised use by Stowing away the hand held control in the crane cab or in the driver s cab Removing the ignition key Locking the driver s cab and the crane cab G Danger due to unauthori...

Page 244: ...Unlocked position and fold the berth 2 down Place the supports 3 into the socket Folding up Turn the locking bar 1 to position Locked Fold out the berth 2 until the locking bar 1 engages in the berth Fold up the supports 3 Put up the back rests of the seats Bring the seats and the steering column into the desired position à Adjusting the driver s seat p 5 13 à Adjusting the passenger seat p 5 14 à...

Page 245: ...ting starting mode for load on Select the Manual operating mode This will allow you to drive carefully and promptly shift gears à p 5 29 Connections If the adjustments to the transmission are insufficient on their own you can additionally connect the following one after the other First you can switch on the off road gear in the transfer case à p 5 50 Then switch on the longitudinal differential lo...

Page 246: ... symbol 1 and confirm it symbol 2 is displayed off road gear engaged The speed is now limited to approx 50 km h 31 mph B Switching off Select symbol 3 and confirm it symbol 4 is displayed off road gear is disengaged If neither the symbol 2 nor 4 is shown select a starting gear on the transmission and shift back into neutral or start up slowly If the error symbol is displayed contact Manitowoc Cran...

Page 247: ...on and off the current speed needs to be under about 5 km h 3 mph Open the Driving 1 menu Straighten the steering Stop the truck crane The symbols 1 and 2 indicate the current switching state and have the same colour Switching on Select and confirm the symbol 1 for the Longitudinal differential locks A or Transverse differential locks B Start moving slowly display first symbol 2 yellow then symbol...

Page 248: ...elect 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 If the error symbol is displayed contact Manitowoc Crane Care ...

Page 249: ...adjustment system menu when the current speed is less than about 5 km h 3 mph Open the Suspension level adjustment 1 menu Check that the symbol 1 is green suspen sion on If the symbol 1 is red then select and confirm the symbol 2 to switch the suspension on When the suspension has been switched on you can Set the on road driving level Pre select the suspension struts and change the vehicle level I...

Page 250: ... level has been reached Pre selecting suspension struts You can pre select the suspension struts for five different level changes For a uniform level change For inclination Select and confirm the desired symbol the symbol turnsorange and the symbol 2 is also displayed Now the vehicle level can be changed with the 7 button 4 Overall level all suspension struts 1 Front level suspension strut for the...

Page 251: ...evel is continuously changed until you release the button or the end position is reached Raise the level Press the button 4 the symbol 1 becomes orange the suspension struts extend Lower level Press the button 5 the symbol 2 becomes orange the suspension struts retract s G Risk of accidents by exceeding total permissible height Always bring the truck crane to on road level before driving on roads ...

Page 252: ... A When the truck crane is level the marking 1 is in the middle B In this example the carrier would be standing higher to the rear on the right hand side Exiting the menu You can exit theSuspension Level adjustment system menu at any time Press the button 1 once The start menu opens or Press the button 2 once The next highest menu is opened The Suspension Level adjustment system menu automatically...

Page 253: ...starting gear with the gearshift lever Press the accelerator as far as possible Start driving as far as you can as high as possible Release the accelerator The transmission declutches disengage Let the truck crane roll in the opposite direction as far as it will go Start driving again to the highest point Repeat driving and letting the truck crane roll back until it has rocked itself free H It doe...

Page 254: ...the rear chassis wall using a shackle The rear towing coupling 1 is designed for a maximum tensile force of 100 kN about 10 t 22 480 lbf about 22 050 lbs if The direction of pull runs along the level of the longitudinal axle and The direction of pull runs along the longitu dinal axle towards the rear without diverting up or down Remove the spare wheel 2 if necessary à p 8 33 S Risk of damage to th...

Page 255: ...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 Crab travel mode When separate steering is switched on you can turn the wheels of the front and rear axle lines in the same direction the truck crane drives sideways ...

Page 256: ...r example Driving around corners If the error symbol is displayed contact Manitowoc Crane Care à p 8 24 H When separate steering is switched on the speed is limited to about 20 m h 12 mph G Risk of accidents when driving on road with unlocked steering After driving with separate steering change over immediately to normal steering mode The locking status for normal steering mode is only restored on...

Page 257: ...The 3rd axle line is steered in the same direction as the 1st and 2nd axle lines The 4th and 5th axle lines are steered in the opposite direction to the 1st and 2nd axle lines B For crab travel mode The 3rd and 5th axle lines are steered in the same direction as the 1st and 2nd axle lines Steering with manual separate steering Steer the 1st and 2nd axle line with the steering wheel Steer the 1st t...

Page 258: ...ing manual GMK5150L 12 01 2018 A For driving around corners Steer the 3rd and 5th axle lines in the oppo site direction to the 1st and 2nd axle lines B For crab travel mode Steer the 3rd and 5th axle line in the same direction as the 1st and 2nd axle line ...

Page 259: ...f the separate steering is possible during standstill and while travelling up to a speed of about 5 km h 3 mph Select and confirm the symbol 1 The Driving menu opens Use the steering wheel 4 and the button 3 to turn the wheels to the Straight ahead posi tion the current wheel position is dis played Select and confirm the symbol 1 symbol 2 is displayed If the error symbol is displayed contact Manit...

Page 260: ... 12 01 2018 5 5 3 Switching units of measure You can display the crane control values in metric units or US units Open the Switch units menu 1 Select and confirm the symbol The symbol 3 shows the respective confirmed selection 1 To display metric units 2 To display US units ...

Page 261: ...e temperature Setting the fan Setting the fan You can regulate the air volume with the switch 1 for Turn the switch 1 to the desired level 1 to 4 Recommended level 2 Setting the temperature Turn the switch 2 to the desired position Press the switch 2 several times in succession at least once a month in order to prevent malfunctions s A Recirculated air air is sucked in from the driver s cab Change...

Page 262: ...e air to flow out of various air vents Turn the switch 5 to the position for the required air vents You can adjust air vents 2 and 3 Adjusting the air vents A Air vents 1 2 front windscreen side B Air vents 1 to 4 C Air vents 2 3 4 side centre below D Air vents 2 3 side centre 1 To open Upwards To close Downwards 2 To direct the air flow ...

Page 263: ...urn the switches to the positions shown If necessary open the air vents for the side and centre If necessary open the push up roof à p 3 71 B Defrosting the front windscreen Turn the switches to the positions shown Close the air vents for the side and centre Switching off Switching off the heating system Turn the switch 1 as far as it will go in a counter clockwise direction to Cold Switching off ...

Page 264: ...ooling output to your actual needs If the truck crane has been exposed to strong sunlight for a long period of time for example the air conditioning system should initially be operated at the highest blower level with the engine running The door or at least the windows should be left open for a short while to thoroughly air the cab The cooling down procedure can be accelerated by increasing the en...

Page 265: ...ution with switch 2 open the air vents if necessary à p 5 66 Close the push up roof à p 3 71 Drying You can dry the air in the driver s cab Switch the air conditioning on the lamp 4 lights up Turn the switch 3 as far as it will go to Warm Turn the switch 1 to the desired level adjust the fresh air recalculated air setting to the current conditions humidity and temperature of the outside air Set th...

Page 266: ...ies at shorter intervals if you use the auxiliary heater frequently Further information on the operation of the auxiliary water heating system is provided at the address Webasto com You can use the auxiliary water heater to preheat the engine or pre heat the engine and driver s cab Preheating the engine If only the engine is to be preheated adjust the heating system as follows Switch 1 pushed in a...

Page 267: ... whether the auxiliary heater is allowed to be operated at the current site of the truck crane before switching it on Find out whether there are any possible sources of danger that could result in an explosion s G Risk of explosion when operating the auxiliary heater The auxiliary heater is not allowed to be operated At service stations and tank farms At places where flammable gases or vapours can...

Page 268: ...n 1 Menu control The jog dial rotary push button 1 turn to select press to confirm Setting the temperature Turn switch 1 to the desired temperature If the switch 1 is turned as far as possible A Cold the auxiliary heater is not switched on The auxiliary heater only supports the heating capacity of the standard heat ing system as long as the engine is cold If the engine is warm the heater is switch...

Page 269: ...8 minutes You must reset the date and time Always set the current time and current day of the week These settings are required for the correct activation point of the automatic heating start Select and confirm the symbol Settings 1 display symbol Immediate start 2 Select and confirm the symbol Day of the week 1 display symbol 2 for instance MON for Monday Select and confirm the desired day of the ...

Page 270: ...g setting process they flash for 5 seconds The entry must be made within this period The value stops flashing after 5 seconds and is saved as the new value Select and confirm the symbol Timer 1 display symbol Add timer 2 Select and confirm the symbol Add timer 2 Select and confirm the desired day of the week for instance MON for Monday The Switch on time display flashes At the flashing display set...

Page 271: ...firm the desired temperature After the desired temperature has been input the set values are saved and shown in the display Day 1 Switch on time 2 Switch off time 3 Heating mode 4 Temperature 5 Confirm the set values Confirm the Activate symbol A heating start that is activated is shown by A white marking 1 The symbol T 2 in the main menu If the display is switched off the button 3 flashes green ...

Page 272: ...2 Switching on Before switching on the heating system check whether it is allowed to be operated at the current location of the truck crane Find out whether there are any possible sources of danger that could result in an explosion G 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 vapou...

Page 273: ...ntil the menu row 2 is displayed If you do not make settings within 10 seconds of switching on the control unit switches to idle mode Use button 1 or 2 to select the symbol 3 and confirm with button 4 The auxiliary heater switches on Setting the heating level You can preselect a heating level between 10 and 30 Use button 1 or 2 to select the symbol 3 and confirm with button 4 Change the heating le...

Page 274: ...ay of the week using button 1 or 2 and confirm with button 4 The set time is shown in display row 3 Select the hour using button 1 or 2 and confirm with button 4 Select the minutes using button 1 or 2 and confirm with button 4 Setting the preselection time Heating is started automatically on schedule only if the time and the day of the week have been correctly set à Setting the day and time p 5 78...

Page 275: ...ect the hour or minutes and confirm with button 4 Use button 1 or 2 to select the Heating function 3 and confirm with button 4 You have now set the preselection time After setting the preselection time you can set the heating period Setting the heating period After an automatic start the auxiliary heater switches itself off as soon as the set heating period has elapsed The heating period applies t...

Page 276: ...splay appears and confirm with button 3 The preselection time is deleted Switching off This section only describes how to switch off the heater manually If the auxiliary heater is switched on automatically it switches off after the set heating period has elapsed à Setting the heating period p 5 79 Use button 1 or 2 to select the symbol 3 and confirm with button 4 The auxiliary heater switches off ...

Page 277: ...s For every 100 kg 220 lbs of drawbar load the axle loads on the 3rd to 5th axle lines are reduced by 60 kg 132 lbs s G 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 Ensure that it is still possible to swivel the front axle of the trailer G Risk of acc...

Page 278: ...r of the trailer is pushed into the coupling jaw The towbar coupling closes automatically and the lever 1 swings downwards H Make sure you check the prescribed condition of the coupling after each coupling procedure The pin 1 may no longer protrude from the guide bushing after the coupling procedure G Risk of injury when the automatic closing device is triggered Do not put your hand into the coupl...

Page 279: ...Socket 2 is designed for special equipment Check the function of the trailer lighting Test the service brake and parking brake immediately after setting off s G Risk of accidents if the trailer is coupled improperly If the pin is protruding from the guide bushing the trailer is not coupled properly and could become disengaged from the towbar coupling while driving G Risk of accidents if the hoses ...

Page 280: ...r Secure the trailer with the trailer parking brake and chocks as prescribed to prevent it from rolling away Open the towbar coupling Push the lever 1 up until it latches into place Drive the truck crane carefully away from the trailer G 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 ...

Page 281: ...sing the towbar coupling by hand When closing the lever moves down with great force in the direction of the coupling jaw Start the closing process only by moving the lever briefly in the direction of the coupling jaw with the ball of your hand If you hold the lever and move it down it may carry your hand with it and crush it G Risk of injury when the automatic closing device is triggered Always cl...

Page 282: ...he lever in this position the parking brake on the trailer is released the parking brake on the truck crane remains applied This allows you to check whether the braking force of the parking brake on the truck crane alone is sufficient to brake the truck crane and the trailer Let go of the lever The lever latches into position and the parking brake of the trailer is applied S Risk of accident from ...

Page 283: ...by the EU partial type approval cannot be met If country specific regulations allow the truck crane to be driven with axle loads greater that 12 t 26 500 lbs the crane driver operator bears the sole responsibility for driving in this condition and for any subsequent damage This also applies to damage due to premature wear G Risk of accidents from increased braking distance When driving with axle l...

Page 284: ...Assume your truck crane is equipped with 385 95 tyres 6 x 10 x 10 drive Equipped with a retarder and towbar for a trailer In addition the auxiliary hoist or the 1 0 t counterweight is mounted In this case the driving mode in the upper part next to equipment is 1 According to the specifications in the lower part in addition to rigging mode the 1 sheave hook block must be attached to the front bumpe...

Page 285: ...x 8 x 10 Retarder Rear bumper Auxiliary hoist or 1 0 t counterweight installed Rigging mode 385 95 R25 spare wheel on rear Storage box at the rear of the carrier Hydraulic hose drum on the main boom 1 8 m 16 m swing away lattice is folded to the side 4 6 t counterweight attached to the turntable 2 3 t counterweight on the counterweight platform 1 sheave hook block attached to the bumper1 Hook tack...

Page 286: ...mode 445 95 R25 spare wheel on rear Storage box at the rear of the carrier loaded with 150 kg Hydraulic hose drum on the main boom 1 8 m 16 m swing away lattice is folded to the side 2 0 m heavy load lattice extension folded to the side 4 6 t counterweight attached to the turntable 2 3 t counterweight on the counterweight platform 1 sheave hook block attached to the bumper1 3 sheave hook block att...

Page 287: ... mode 525 80 R25 spare wheel on rear Storage box at the rear of the carrier loaded with 150 kg Hydraulic hose drum on the main boom 1 8 m 16 m swing away lattice is folded to the side 2 0 m heavy load lattice extension folded to the side 4 6 t counterweight attached to the turntable 2 3 t counterweight on the counterweight platform 1 sheave hook block attached to the bumper1 3 sheave hook block at...

Page 288: ...um values Also note the information provided by the tyre manufacturer regarding the maximum permitted load duration G Risk of accidents from overloading tyres Never exceed the maximum permitted speed which is given for the current axle load and tyre size This prevents the tyres from becoming overloaded and bursting Tyre size Tyre pressure in bar psi Current Axle load in t lbs Maximum permissi ble ...

Page 289: ...by the manufacturer of the scales If multiple individual scales are used allowance must be made for the fact that the axle groups are hydraulically coupled For this purpose you will need wheel load scales of sufficient capacity and size Determining the total weight The weights of all the axle groups belonging to the crane must be recorded at the same time in a single weighing procedure In addi tio...

Page 290: ...e axle lines belonging to an axle group must always be weighed In addition all the wheels must be on the same level If for instance only the axle group A1 is to be weighed then the axle groups A2 must be equalised on a support plate U which has the same height as the scales W1 and W2 Axle groups GMK5150L Axle group 1 1 2 axle lines Axle group 2 3 4 5 axle lines ...

Page 291: ... groups 1 and 2 In the next step drive at only a very low speed without any steering movements and brake only very gently Drive the truck crane on to the scales W1 to W4 or on to the necessary support plates so that the axle groups stand centrally on the scales Do not apply the parking brake If the truck crane has to be braked while changing the level only use the service brake very gently 1 Use t...

Page 292: ...le lines You must determine the weight of the associated axle group and divide it by the number of axle lines Determine the weight of the axle group The axle group 2 was weighed with the scales W3 and W4 Add the weighing results Determining the axle load on the 2nd axle line Axle group 2 has 3 axle lines Divide the weight of the axle group by the number of axle lines Passenger side W1 10 t W3 12 t...

Page 293: ... in which you are working you can set the main boom onto 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 Before driving with the dolly you must Switch on the slewing gear freewheel à p 6 12 Switch on the boom floating position à p 6 13 Switch on boom pre tensioning if necess...

Page 294: ... position p 6 13 Prerequisites The engine must be running The slewing gear brake must be released the lamp 1 must have gone out à Releasing the slewing gear brake p 11 116 Switching on Remove the lock 4 from the bore 2 Push the pin 3 inward as far as it will go Secure the pin with the padlock in the bore 1 and remove the key Insert and secure the pin 3 on the other slewing gear in the same way Ope...

Page 295: ... valve I lever 1 upwards Secure the lever 1 with the padlock 2 Switch the valve IV over Lever 3 points downwards The boom floating position is now switched on H Switching off the boom floating position à p 12 19 G Risk of accidents from the boom floating position being switched off Always switch on the boom floating position when the main boom is on a dolly This prevents the full weight of the dol...

Page 296: ...sioning Switch on the boom floating position à p 6 13 The valves II and III are under the pressure gauge 1 Close the valve II the lever 2 is horizontal Open the valve III the lever 3 points upward You can now fill the pressure accumulator Press button 4 in The pressure accumulator is now filled Fill up the pressure accumulator until the pressure stops rising on the pressure gauge 1 Close the valve...

Page 297: ...vel adjustment system to lower the truck crane to its lowest position à p 5 54 Remove the padlocks 2 Switch over valves I and II levers 1 forwards Secure the levers 1 with the padlocks 2 Establish the on road level à p 5 54 Lowering Use the level adjustment system to lower the truck crane to its lowest position à p 5 54 Remove the padlocks 2 Switch over valves I and II levers 1 backwards Secure th...

Page 298: ...Driving modes and rigging for on road driving 6 3 Rigging work for driving with a dolly 6 16 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 299: ...ing cylinder support 1 a tightening belt 2 a lifting device 3 lifting gear 4 as well as an auxiliary crane with sufficient lifting capacity a separate vehicle with sufficient load bearing capacity and loading area Transport dimensions and weight à p 1 10 G Risk of accident when removing installing the main boom without pulling devices Only remove or install the main boom if the truck crane is equi...

Page 300: ...nsions have been removed All telescopic sections are fully retracted and locked The hook block has been unreeved and the hoist rope has been reeled on the drum up to the main hoist The superstructure is slewed to the front The truck crane is supported with at least an outrigger span of 8 030 x 2 50 m 26 3 x 8 2 ft Or the parking brake is applied the truck crane has been aligned horizon tally with ...

Page 301: ...om rest 5 Sling the main boom to an auxiliary crane à p 6 26 6 Switch on the derricking cylinder pressure relief à p 6 29 7 On the derricking cylinder head axle Take the load off of the head pin Release the head pin pull the head pin out à p 6 30 8 On the boom pivot pin Switch the hydraulic circuit over Release the pivot pin Pull out the pivot pin à p 6 32 s ...

Page 302: ...ng the main boom 6 20 3 302 709 en Operating manual GMK5150L 12 01 2018 9 Raise the main boom from the turntable 10 Put the main boom on the separate vehicle and secure for transport à p 6 35 11 Secure the derricking cylinder with a tightening belt à p 6 35 ...

Page 303: ... warnings and safety instructions specified there Prerequisites The truck crane is supported with at least an outrigger span of 8 030 x 2 50 m 26 3 x 8 2 ft Or the parking brake is applied the truck crane has been aligned horizon tally with the level adjustment system and the suspension is locked Checklist 1 Check whether the pressure relief for the derricking cylinder is switched on à p 6 29 2 Re...

Page 304: ...36 5 On the boom pivot pin Push in the pivot pin secure the pivot pin Switch the hydraulic circuit over à p 6 32 6 Set down the main boom in the boom rest with the auxiliary crane and remove the lifting gear 7 On the derricking cylinder head axle Level the derricking cylinder Fit the head pin Secure the head pin à p 6 30 8 Switch off the derricking cylinder pressure relief à p 6 29 9 Raise the mai...

Page 305: ...ting manual 3 302 709 en 6 23 GMK5150L 12 01 2018 10 Establish the hydraulic electric connection à p 6 24 11 Remove the derricking cylinder support from the counterweight platform 12 Place the main boom on the boom rest 13 Perform inspections with the main boom set down à p 6 37 ...

Page 306: ... sockets If necessary secure all the hoses cables so that they do not swing loose when the main boom is raised S Risk of malfunction in the superstructure electronics Always turn off the ignition in the crane cab before you establish or sepa rate the electrical connection This prevents malfunctions in the electronics and corresponding error messages in the subsequent crane operation G Danger of ha...

Page 307: ...2018 Establish Remove the bridging plug 3 Connect the plug 4 to the socket Connect all hoses 1 to the connections 2 The assignment is given by the size and col our designations Lay the hoses cables so that they will not be damaged Insert the clamp 2 onto the pins 3 Secure the clamp using the linch pins Replace the plate 1 ...

Page 308: ... and before on road driving 6 4 5 Slinging the main boom Slings are fitted to the main boom when rigging and it is lifted with an auxiliary crane Note the equipment necessary for this à p 6 17 Marking The lifting gear is labelled Only connect the parts of the lifting gear that have the same marking Only fasten the lifting gear to the slinging points intended for this purpose The markings are of fo...

Page 309: ...he retaining pins Install the front bracket first It hangs on longer ropes which makes installing the back bracket easier 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 A Pull the bracket to the centre the bracket must rest on the slinging point on both sides B Install the bracket 5 ...

Page 310: ...oving the sling gear Remove the pin 2 and pull the bracket 5 out of the slinging point 4 Secure the bracket with the pin 2 and the retaining pin Pull the bracket out of the slinging point 1 Position the lifting gear such that the bracket 3 is relieved Remove the bracket 3 in the same manner Put down the lifting gear for transport ...

Page 311: ...nder head axle When installing Only switch off the pressure relief after fitting the derricking cylinder head axle Remove the lock 2 A Switching on Switch over valve I lever 1 upwards B Switching off Switch over valve I lever 1 horizontal and pointing outward Secure the lever with the lock 2 and remove the key H When the pressure relief is switched on the main boom cannot be raised G Risk of accid...

Page 312: ...od 3 extends B Lower Slowly open the drain plug 1 The piston rod 3 retracts Pulling the derrickingcylinder head axle After you have pulled the head pin you can not longer derrick the main boom A Releasing the head pin Remove the disc 3 B Taking the load off of the head pin Place the lifting device 2 underneath the middle of the derricking cylinder Carry out the movement Raise until the shelf 1 is ...

Page 313: ...vice Fitting the derrickingcylinder head axle Check to see if the tightening belt of the derricking cylinder is taken off Aligning the derricking cylinder A Remove the disc 1 Place the lifting device 2 underneath the middle of the derricking cylinder B Carry out the movement Raise until the head pin 4 is aligned with the bearing in the derricking cylinder 3 s G Risk of accident from falling derric...

Page 314: ...n Before pulling out you must switch the hydraulic circuit over and the pivot pins must be released S 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 G Risk of accidents due to the main boom falling down The pulling dev...

Page 315: ... into the connect ing points 3 Secure the pins 1 Release the pivot pins on the other side in the same way Open the Superstructure lock menu 1 if necessary Pulling out the pivot pin Start the engine from the crane cab à p 10 3 Select the symbol 1 Press and hold 2 or 3 button until the pivot pins 4 are completely pulled out on both sides Switch the engine off s S Risk of damage to the main boom Befo...

Page 316: ...ne cab à p 10 3 Select the symbol 1 Press and hold 2 or 3 button until the pivot pins 4 are completely pushed in on both sides Switch the engine off Securing the pivot pins Remove the pins 1 from the connecting points 3 and insert them into the connect ing points 2 Secure the pins 1 Secure the pivot pins on the other side in the same way Switching over the hydraulic circuit Switch over valves leve...

Page 317: ... risk Load the transport vehicle in such a way that the weight is evenly distributed Secure the connection lines so that they will not slip and be damaged during transport 6 4 10 Securing releasing the derricking cylinder A Securing Place the tightening belt 1 over the derricking cylinder and fasten it onto the holders 2 Tighten the tightening belt so that the der ricking cylinder is secure within...

Page 318: ...e driver s cab The connecting points are not tilted Lay the hoses into the turntable in such as way that they are not damaged during alignment Align the main boom so that the boom pivot pin is aligned with the bearing points 1 in the turntable Hold the main boom in this position until the pivot pin is pushed in S Risk of damage to the turntable and the connection lines Make sure that the connectio...

Page 319: ...s on outriggers The main boom is resting in the boom rest The current rigging mode must have been entered and confirmed on the RCL display Telescope the telescopic section about 1 m out and back in Retract the telescoping cylinder into another telescopic section and mechanically lock it there Check to see if the hydraulic connections in the turntable are sealed H Before operating for the first tim...

Page 320: ...Driving modes and rigging for on road driving 6 4 Rigging the main boom 6 38 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 321: ...opes A separate vehicle Transport dimensions and weight à p 1 13 6 5 1 Slinging the auxiliary hoist Sling the auxiliary hoist at the slinging points 1 Use suitable lifting gear with the same length so that the auxiliary hoist hangs at the centre of gravity If necessary remove the pins from the connecting points S Risk of damage to the auxiliary hoist and truck crane Only sling the auxiliary hoist ...

Page 322: ...xiliary hoist at the centre of gravity and remove the pins from the connection points à p 6 39 2 Lift the auxiliary hoist on to the turntable and make the connections à p 6 42 3 Make the hydraulic connections à p 6 43 Make the electrical connection à p 6 44 Establish the connection to the central lubrication à p 6 45 4 Check that the auxiliary hoist is functioning properly à p 6 47 5 Fit the hoist...

Page 323: ...t rope using the rigging aid if necessary à p 6 48 2 Disconnecting hydraulic connections à p 6 43 Disconnecting the electrical connection à p 6 44 Disconnect the connection to the central lubrication à p 6 45 3 Attach the auxiliary hoist at the centre of gravity à p 6 42 Disconnect the connection between the auxiliary hoist and turntable à p 6 42 4 Lift the auxiliary hoist onto the separate vehicl...

Page 324: ... Making the connection Suspend the auxiliary hoise in the connect ing points 3 at the turntable Lower the auxiliary hoist until the connect ing points 2 align Insert the pins 1 and secure them Undoing the connection Attach the auxiliary hoist on to an auxiliary crane Remove the pins 1 from the connecting points 2 Lift the auxiliary hoist off the turntable Lift the auxiliary hoist on to a separate ...

Page 325: ...01 2018 6 5 5 Establishing disconnecting the hydraulic connections Making the connection The assignment is given by the size and colour designations Connect the hoses 1 to the connections 2 Undoing the connection Remove the hoses 1 from the connec tions 2 Close all hoses and connections Insert the hoses into the hoist frame 3 ...

Page 326: ...ting establishing the electrical connection Making the connection Remove the plug 2 from the dummy socket 3 and plug it into the socket 1 Close the dummy socket 3 Undoing the connection Remove the plug 2 from the socket 1 and plug it into the dummy socket 3 Close the socket 1 Lay the cable 4 in such a way that it is not left hanging during removal ...

Page 327: ...02 709 en 6 45 GMK5150L 12 01 2018 6 5 7 Making breaking the connection to the central lubrication Making the connection Connect the hose 1 to the connection 2 Undoing the connection Remove the hose 1 from the connec tion 2 Close off the hose and the connection Insert the hose into the hoist frame 3 ...

Page 328: ... capacity Transport dimensions and weight à p 1 21 Load the separate vehicle in such a way that the weight is evenly distributed Load the auxiliary hoist in such a way that no motorists and cyclists are put at risk Lift the auxiliary hoist onto the separate vehicle and remove the lifting gear Check that the plug 1 is inserted into the dummy socket Lay the hoses and cables 3 aside so they will be b...

Page 329: ...the slewing direction is correct Slewing indicator Check the function of the slewing indicator when applying the hoist rope You should feel a pulse on the slewing indicator 1 when the auxiliary hoist is rotating If no pulse is present contact Manitowoc Crane Care G Risk of accidents due to incorrect slewing direction Check after each installation that the slewing direction is correct This prevents...

Page 330: ...s provided with the auxiliary hoist Scope of delivery Making the connection Place the end of the hoist rope 1 in part 2 of the connector Screw part 2 and 3 of the connector together Attach the rope 4 to the connector 1 Connector two parts 2 Rope S Risk of damage to the hoist rope Always rig the hoist rope with the rigging aid This prevents slack rope Rope loops will form which can cause the load t...

Page 331: ...over the upper head sheave Slowly unreel the hoist rope Use the rope 1 to keep the hoist rope tensioned so that no slack rope occurs When unrigging Slowly reel in the hoist rope Use the rope 1 to keep the hoist rope tensioned so that no slack rope occurs Undoing the connection Remove the rope 4 Disconnect part 2 and 3 of the connector and remove the hoist rope 1 Store the rigging aid so that it is...

Page 332: ...Driving modes and rigging for on road driving 6 5 Rigging the auxiliary hoist 6 50 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 333: ...linders and add on parts You will require the following equipment with a sufficient load bearing capacity An auxiliary crane Suitable lifting gear and guide ropes A chain hoist A separate vehicle Dimensions and weights of the outrigger beams à p 1 10 G Risk of truck crane overturning if not properly supported Loads may only be lifted when the truck crane is supported on all outrigger beams The lif...

Page 334: ...re are accompanying operating instructions which are indicated by cross references Observe the warnings and safety instructions specified here 1 Preparing the truck crane à p 6 57 2 Label the outrigger beams retract release and bolt them to each other à p 6 56 3 If necessary remove the outrigger pads à p 6 58 4 Unscrew the spacer à p 6 62 5 Disconnecting hydraulic connections à p 6 60 Disconnect t...

Page 335: ...it out of the outrigger box until it reaches the centre of gravity à p 6 64 8 Sling the outrigger beams in the centre of gravity and pull them out of the outrigger box Lift the outrigger beams onto the separate vehicle Attach the connecting elements on the outrigger box à Extending the outrigger beam p 6 64 à Transporting the outrigger beams p 6 68 9 Remove all necessary outrigger beams in the sam...

Page 336: ...ety instructions specified here 1 Preparing the truck crane à p 6 57 2 Remove the connection elements from the outrigger box Sling the outrigger beams at their centre of gravity Lift the outrigger beams into the outrigger boxes and remove the lifting gear à Inserting the outrigger beam p 6 66 3 Sling the outrigger beams and pull into the outrigger boxes until the connection points align à p 6 66 4...

Page 337: ...ing pads into position à p 6 58 8 Mount all necessary outrigger beams in the same way in accordance with this checklist 9 If the truck crane is at the site Extend the outrigger beams to the necessary outrigger span secure them and stabilize the truck crane 10 If the truck crane still has to be driven to the site Fully retract and secure the outrigger beams à Extending retracting outrigger beams p ...

Page 338: ...er beam is designed for just one installation point If for exam ple you remove the outrigger beam on the rear left hand side you must mount the same outrigger beam on the rear left hand side again Before you remove all outrigger beams for the first time label them with the correct installation point and if necessary also with the serial number of the truck crane Release the outrigger beams All out...

Page 339: ...uisites The following requirements must be met before mounting removing the outrigger beams All rigging work which involves slewing the superstructure has been completed The parking brake is engaged The truck crane has been levelled with the level adjustment system à p 5 53 The suspension is switched off blocked and the symbol 1 is red à p 5 16 The corresponding covers have been removed 1 ...

Page 340: ...g frame the outrigger beams can be set down on the outrigger pad Removing the outrigger pads Handling is easier if you remove the outrigger pad before removing the out rigger beams A Move the outrigger pad into the operating position Remove the pins 1 Extend the outrigger cylinder until the out rigger pad just touches the ground but is not yet under strain B Pull the outrigger pad off the outrigge...

Page 341: ...ger pad A Remove the pin 1 Extend the outrigger cylinder far enough so that the bearing surface 3 is below the guide 2 Push the outrigger pad onto the outrigger cylinder Move the outrigger pad into required posi tion On site move it to the working posi tion B If you need to drive to the site in driving position C Insert the pins 1 and secure them Securing pin Plug the pin with the peg 1 through th...

Page 342: ... The position of the valve block may differ from the drawings depending on the outrigger beam Undoing the connection Always disconnect all connections 4 Hold the hose 1 firmly Pull the lock 2 against the stop The hose is pushed out of the connection 3 Seal all connecting points Making the connection Always establish all connections 4 The assignment is specified by colour designations Insert the ho...

Page 343: ...onnection Pull the plugs 1 apart Protect the plugs against dirt and moisture B Establishing the connection Connect the plugs 1 together Protect the separating points against dirt and moisture H Some error messages can occur after disconnecting the electrical connec tions à Note on error messages with removed outrigger beams p 6 68 S Risk of malfunctions in the electronic system Always turn off the...

Page 344: ...er beam on the opposite side The illustrations show as an example the spacers for the outrigger beam on the front right hand side Unscrewing Before you pull out the outrigger beams you must unscrew the spacers At the outrigger box Undo the lug nuts 2 Unscrew the bolts 1 until the spacers 3 are screwed into the outrigger box 4 completely At the outrigger beam Undo the lug nuts 2 Unscrew the bolts 1...

Page 345: ...he outrigger box Screw in the screws 1 as far as possible until the spacers 3 are touching the outrigger beam 4 at the top Ensure that the outrigger beam is aligned horizontally Lock the screws in place with the nuts 2 At the outrigger beam Screw in the bolts 1 Until the spacers 3 lie on top on the outrigger box 4 and Until the distance X to the supporting box 4 is an even 4 mm 0 16 in over the en...

Page 346: ... the attachment plates 4 still have lateral play 6 6 11 Pulling out Inserting the outrigger beam Extending the outrigger beam Check that the outrigger beams are released and are secured between each other à Preparations for removal p 6 56 S Risk of damage to hydraulic lines Ensure that the hydraulic lines on the outrigger beam do not remain hanging on the supporting box and become damaged G Danger...

Page 347: ...and lifting gear Fasten a guide rope 1 Lift the outrigger beam slightly to ease the load Lift the outrigger beam almost completely out of the outrigger box Fasten another guide rope 1 Lift the outrigger beam out of the outrigger box Lift the outrigger beam onto a separate vehicle à p 6 68 Fasten the connecting elements to the connecting points 1 of the supports s G Risk of being crushed by the swi...

Page 348: ...y data p 6 56 Fasten two guide ropes 1 Set the outrigger beam in the outrigger box Remove the guide rope 1 G Risk of being crushed by the swinging outrigger beam Do not guide the outrigger beam with your hands when inserting it Always used guide ropes and keep a suitable distance This will prevent limbs from being crushed between the supporting box and the outrigger beam S Risk of damage to hydrau...

Page 349: ...018 Lift the outrigger beam as far as possible into the outrigger box Correct the height so that it does not remain hanging on the edges 1 Remove the lifting gear from the centre of gravity Fasten a chain hoist to the lifting gear 1 Pull the outrigger beam in so far until the connecting points 1 align Remove the chain hoist and lifting gear ...

Page 350: ... beam from slipping When the outrigger pads are dismounted Lay the outrigger beam onto the side Secure the outrigger beam from slipping Lay the outrigger pads onto the separate vehicle and secure them for transportation 6 6 13 Note on error messages with removed outrigger beams When the outrigger beams have been removed certain error messages appear on the CCS display The error messages indicate o...

Page 351: ... only suitable lifting gear with sufficient lifting capacity for loading Use only trailers and vehicles with sufficient loading surface and carrying capacity for transport G Risk of accidents due to inadequate information Observe the information in the following sections concerning transport You can thus prevent unsecured parts from falling or components from being damaged due to improper handling...

Page 352: ...h telescopic section I The boom must be resting in the boom rest The slewing gear is switched off à p 11 120 The superstructure is locked à p 11 15 Depending on the driving mode the counterweight must be unrigged à p 6 1 à p 12 71 2 On the outriggers All outrigger beams must be fully retracted and secured to prevent extension à p 12 46 The outrigger pads are in the driving position à p 12 53 3 All...

Page 353: ...e anemometer and air traffic control light must be removed à Anemometer and air traffic control light p 12 145 5 All railings must be folded in à p 12 149 6 The camera on the turntable must be retracted à p 12 152 7 The step at the crane cab must be retracted à p 12 157 8 All ladders are secured à p 3 77 s ...

Page 354: ... block must be attached to the bumper à p 12 115 or unreeved à Unreeving hoist rope p 12 131 11 The transverse differential locks must be switched on à p 5 51 7 1 2 Drive the truck crane on to the transport vehicle G Risk of accidents due to inadequate field of vision Always have a banksman on hand to help when driving onto a transport vehicle Maintain eye contact or radio contact with the banksma...

Page 355: ...mediately and switch the engine off Close all the doors Lashing Secure the truck crane with the chocks 1 Lash the truck crane down at the slinging points 2 Ensure that no attachments cables or hoses are damaged in this process G Risk of accidents due to falling parts Use only suitable lifting gear with sufficient load bearing capacity and use only the slinging points provided ...

Page 356: ...sides Ensure that no attachments cables or hoses are damaged in this process Additional slinging points are usually neces sary when the truck crane is transported on a ship If necessary use additional points as slinging points G Risk of accidents due to falling parts Use only suitable lifting gear with sufficient load bearing capacity and use only the slinging points provided 1 Main boom head 2 Ma...

Page 357: ...mergency use Press an emergency stop switch 1 2 or 3 The switch latches The engine shuts down After activating an emergency stop switch à Resetting the emergency stop switch p 4 19 H The battery master switch cannot be used as an emergency stop switch for the engine The engine continues to run after the battery master switch has been switched off 1 On the carrier 2 On the hand held control unit 3 ...

Page 358: ...the traffic behind you Secure the truck crane in compliance with the legal regulations applicable in the country in which you are working If you are unable to repair the damage yourself notify Manitowoc Crane Care or have the truck crane towed à Towing the truck crane p 8 29 G Risk of accidents due to poor visibility If possible do not stop in a tunnel or directly after a curve G Risk of accidents...

Page 359: ...ngine malfunction One or more systems have a malfunction Engine Engine cooling system Engine control Fuel system Drive on until you have a chance to stop Stop immediately and switch the engine off If necessary note the error messages and contact Manitowoc Crane Care or a qualified specialist repair shop The coolant temperature is too high the motor output is automatically reduced Reduce speed Driv...

Page 360: ...nic system will try to establish a secure operating condition with the remaining functions H Even if the transmission still shifts always notify Manitowoc Crane Care This avoid situations where another small error could lead to transmission failure A text message is also displayed in addition to a symbol on the on board computer display à Warning and malfunction messages on the on board computer d...

Page 361: ...function message is active in the corresponding area Lamp goes out no message Lamp is red warning message Stop the truck crane immediately taking into account the traffic situation and identify the cause Lamp is orange malfunction message Identify the cause at the next opportunity If a symbol is displayed in red perform the following checks Battery charge indicator warning The voltage in the carri...

Page 362: ... the hydraulic oil level à Maintenance manual Start the engine If all 3 lamps 1 light up Switch the engine off Contact Manitowoc Crane Care If at least 2 lamps 1 light up Drive at a speed greater than about 10 km h 6 mph If only one lamp is still lit drive slowly to the next repair shop The steering may be sluggish If two lamps are still lit stop immediately Contact Manitowoc Crane Care G Risk of ...

Page 363: ...tunity Steering system warning The lamp 1 lights up symbol 2 red There may be an error at the 3rd axle line or at the 4th axle line or at both axle lines The affected axle line stays on the current steering angle and can no longer steered Stop as quickly as possible taking account of the current traffic situation Briefly switch the ignition off and then on again If the error is still present then ...

Page 364: ...ions in driving mode 8 3 Warning and error messages 8 8 3 302 709 en Operating manual GMK5150L 12 01 2018 AdBlue system Also check the control elements for the Adblue system à Faults on the Adblue system p 8 21 ...

Page 365: ...rmation Display 1 grey additional text and symbols Pay attention to the messages You can continue driving Message elements Messages consist of text and symbols abbreviations When the symbol 1 is shown you can dis play additional text by pressing the button 3 Follow the instructions that are displayed and perform the specified measures in good time Acknowledging a message Press 2 once the message d...

Page 366: ...dd oil if necessary If the error message is still displayed please contact Manitowoc Crane Care Oil level too low The oil level is far too low Stop the truck crane as quickly as possible while observing the traffic situation and switch off the engine If oil has run out Warn any vehicles on the road behind you Do not continue driving Contact Manitowoc Crane Care If no oil has run out Correct the oi...

Page 367: ...alfunction Engine retarder fault The braking behaviour can change Stop the truck crane as quickly as possible while observing the traffic situation and switch off the engine Have the engine retarder immediately checked and repaired by a specialist workshop Transmission symbols The gear shifting has a malfunction driving can continue with restrictions If necessary note the error messages and contac...

Page 368: ...as been reached Shift to a lower gear for manoeuvring or starting or Stop the manoeuvring or starting procedure The oil temperature of the fluid coupling is too high Shift to a lower gear the engine speed increases and the dry clutch closes The oil temperature of the retarder is too high Shift to a lower gear the engine speed increases and the engine braking effect increases ...

Page 369: ...lfunction message is active in the corresponding area Symbol yellow malfunction Symbol red warning message No symbol no malfunction or warning message If a symbol is displayed in red or yellow perform the following checks Symbols in the display area Voltage monitoring The voltage in the electrical system is too high or too low Display of the current voltage à p 4 17 s S Risk of damage if warning m...

Page 370: ... level is correct then start the engine and check the warning mes sages that are present Air intake inhibitor triggered The air intake inhibitor was triggered because the maximum permissible engine speed was exceeded It is only possible to start the engine after the air intake inhibitor has been released manually à p 4 20 S Danger of overheating There is a fault if the hydraulic oil temperature ex...

Page 371: ...ut 95 C Display of the current temperature à p 10 8 Possible cause and remedy à p 8 19 Transmission retarder too hot The retarder in the transmission is not working When the transmission retarder has cooled down the symbol reverts to grey and the transmission retarder is ready to function again Transmission oil too hot Stop the truck crane as soon as possible and try to find the cause à Malfunctio...

Page 372: ...oom rest the specified vehi cle height for the on road level is exceeded à Checking the vehicle height p 5 9 Emergency stop switch actuated à Resetting the emergency stop switch p 4 19 Engine malfunction Switch off the engine immediately and open the Engine error menu à p 8 17 If necessary note the error messages and contact Manitowoc Crane Care CAN bus malfunction Switch off the ignition and wait...

Page 373: ...es are present 1 Crane operation error The buzzer tone sounds once Open the Crane operation error menu 2 à Special error messages p 8 18 3 Engine transmission error Switch off the engine immediately Open the Engine transmission error menu 4 Display of error total errors Display 2 shows the error total and display 1 shows which error is displayed 3 5 for example means Error 3 is shown there is a to...

Page 374: ...ave been acknowledged then the symbol 1 will be dis played continuously When all errors are acknowledged the symbol 1 goes out The buzzer tone sounds once and the symbol 1 flashes when an error occurs Special error messages The error messages listed here are shown after the removal of the outrigger beams and cannot be acknowledged The error messages have no effect on driving and will no longer be ...

Page 375: ...e à p 5 46 Fuse F1 1 F1 2 blown Replace blown fuses à p 8 49 Emergency stop switch pressed Release the emergency stop switch à p 4 19 Engine does not start Starter turns Batteries insufficiently charged Charge the batteries à Maintenance manual The symbol is displayed Fuel tank empty 1 Refuel à p 4 5 2 Bleed the fuel system à Maintenance manual à Separate engine operating instructions provided by ...

Page 376: ... the symbol is displayed Engine oil level too low Check oil level top up if nec essary à Maintenance man ual Engine cannot be switched off using the ignition key Malfunction in the elec tronics Switch off the engine with the emergency stop device à p 8 1 Engine transmission diagnostics plug not working Fuse F1 5 F6 6 blown Replace blown fuses à p 8 49 The engine power is reduced and the engine coo...

Page 377: ...oes not start Starter turns Dual tank empty 1 Refuel à p 4 5 2 Bleed the fuel system à Maintenance manual à Operating manual of the engine manufacturer Malfunction Cause Solution Lights up Flashing AdBlue level in tank at reserve level AdBlue tank empty Fill up with AdBlue à p 4 7 Light up AdBlue tank sensor faulty Error on the AdBlue dosing unit AdBlue lines blocked Temperature sensor faulty Open...

Page 378: ...ir system insufficiently filled à Building up supply pressure p 5 10 Control unit fuse blown Replace blown fuses à p 8 49 Differential locks cannot be switched off Current speed above about 5 km h 3 mph Slow down or stop the truck crane Drive train under tension Slowly drive truck crane back and forth à p 5 51 Malfunction Cause Solution Switching operations are not conducted Brake reservoir pressu...

Page 379: ...sion is not upshifting at speeds over about 20 km h 12 mph A locking procedure is not yet completed Switch off differential locks à p 5 52 Transmission not shifting the symbol is displayed Retarder switched on à Switching off the additional brakes p 5 43 The transmission does not respond to the controls Fuse F1 6 blown Replace blown fuses à p 8 49 Transmission cannot shift down as otherwise the ma...

Page 380: ...ing circuit has failed e g pump faulty Stop and perform required inspections à p 8 6 Lights up yellow Steering malfunction Driving possible observe the subsequent informa tion for the next stop à p 8 7 lights up red Steering system warning The steering is defective stop as quickly as possible and observe the subse quent information à p 8 7 Symbol is displayed Hydraulic oil filter dirty Replace the...

Page 381: ...op up the compressed air supply on the filler connection à p 8 29 2 Tow the truck crane with the tow rod à p 8 29 Parking brake una ble to be released Supply pressure too low à Building up supply pressure p 5 10 The retarder can not be engaged Fuse F7 4 blown Replace blown fuses à p 8 50 Malfunction Cause Solution Suspension cannot be activated Current speed above about 5 km h 3 mph Slow down or s...

Page 382: ... Replace blown fuses à p 8 49 Malfunction Cause Solution Hydraulic oil temperature above 80 C 176 F fan in the hydraulic oil cooler running Symbol is displayed Hydraulic system is heavily loaded Stop the truck crane while taking the traffic situation into account and run the engine until the oil has cooled down Hydraulic oil temperature above 80 C 176 F fan in the hydraulic oil cooler not running ...

Page 383: ...arting the truck crane externally Start the engine of the auxiliary vehicle A Connect the cable 1 to the power supply 24 V of the auxiliary vehicle Insert the plug 2 into socket 3 Start the truck crane engine B Take out the plug 2 Close the socket 3 Remove the cable 1 from the auxiliary vehicle The socket 3 can also be used as a power source for another vehicle with a 24 V on board network ...

Page 384: ...g eyes 5 Insert the plug 3 into the socket on the mains supply 230 V at the location The battery charger switches on The lamp 6 on the battery charger indicates the status Breaking Withdraw the plug 3 from the socket Take out the plug 2 from the socket 1 Close the socket 1 Return the battery charger to the storage compartment in the driver s cab G Risk of explosion when operating the battery charg...

Page 385: ...owed with a special breakdown truck The front towing coupling is designed for a maximum tractive force of 10 t 22 000 lbs Tensile force may be applied only forwards or at an angle of 45 to both sides of the longitudinal axis of the truck crane In the case of engine transmis sion damage The following information only applies to towing the truck crane out of the immediate hazard area in the event of...

Page 386: ...essure of at least 6 bar 87 psi must be displayed and the lamps 1 must not light up in the driver s cab when towing Electric power supply Switch on the battery master switch Switch on the ignition On the transmission Switch the transmission to neutral position N à p 5 26 Axle drives Switch off all differential locks The symbols 1 and 2 must be green Transverse differential locks à p 5 51 Longitudi...

Page 387: ...switching state for example for on road driving Parking brake Release the parking brake The lamp 1 must go out If the lamp continues to light up the supply pressure may be too low Let the engine of the truck crane or towing vehicle run on the compressed air supply until the supply pressure has been built up à Building up supply pressure p 5 10 If the lamp 1 does not go out there is a malfunction o...

Page 388: ...d 100 m 330 ft Longer towing distances If a vehicle with automatic transmission is to be towed for a distance greater than 100 m 330 ft you must disconnect the Cardan shaft between the transfer case and transmission If you need to tow the truck crane further than 100 m 330 ft contact Manitowoc Crane Care Tow starting Tow starting is not possible for reasons related to the transmission S Risk of da...

Page 389: ...elect as flat a place as possible to change the wheel Apply the parking brake s G Risk of accidents due to a wheel falling over If you temporarily lean a wheel against the truck crane while changing it secure it with a rope to prevent it falling over Move the outriggers only when no wheel is leaning against the truck crane G Risk of crushing due to turning wheels When you start the engine no perso...

Page 390: ... crane then Support the truck crane Enter and confirm the current rigging mode Lift the spare wheel using only lifting gear with sufficient load bearing capacity à Spare wheel p 1 10 G Risk of accidents due to a wheel falling over When unscrewing the final lug nuts the wheel can slip off the hub and fall toward you Secure the wheel and step back quickly if the wheel begins to tip G Danger of overt...

Page 391: ...brake light must be reattached Removing A Remove the nuts 2 B Put the brake light 1 into the holder Undo the nuts 2 Installation B Remove the nuts 2 A Fit the brake light 1 onto the holder 3 Secure the brake light with the nuts 2 Removing a wheel Remove the nuts 1 Lift the spare wheel off the holder Secure the spare wheel against falling over if you put it down temporarily Mounting a wheel Lift th...

Page 392: ...wheel studs are not damaged Tighten the wheel nuts 1 and 2 finger tight to secure the wheel Tighten the remaining wheel nuts finger tight Always tighten the wheel nuts in the order 1 to 12 Tighten all wheel nuts first to 200 Nm 150 lbf ft Then all lug nuts to 400 Nm 300 lbf ft Finally tighten all wheel nuts to 650 Nm 480 lbf ft After 50 km 30 mi and 150 km 90 mi retighten all wheel nuts to 650 Nm ...

Page 393: ...er you have inflated the tyres yourself always drive directly to a service station or repair shop and adjust the tyre pressure The filling hose has a tyre inflator connection 2 and a connection 1 Connecting the filling hose Remove the caps 2 and 4 Fasten the connection 3 to the filler connection 1 You can now inflate the tyres s S Risk of damage if the tyre pressure is too high Depending on the si...

Page 394: ...nection and inflate the tyre Disconnect the tyre connection 1 from the tyre valve Remove the filling hose Before driving you must remove the tyre filling hose from the tyre inflator connection Remove the connection 1 from the filler connection 2 Close the filler connection and the connec tion with the caps 2 and 4 Stow the filling hose away Drive to a service station or repair shop and adjust the ...

Page 395: ...xle line can then no longer be steered from the driver s cab or from the crane cab In this case you can steer the wheels of the defective axle line with the emergency operation to the straight running position in order to enable a drive to the workshop 3rd axle line operating element Remove the cover 1 Fasten the covering 1 after the emergency operation 4th axle line operating element Remove the c...

Page 396: ...e out two fuses Take out fuses You must take out two fuses before the emergency operation so that the steering system electronics is deactivated Turn off the ignition Take the fuses F2 4 and F2 5 out à Fuses in the driver s cab p 8 50 Take the fuse F10 out à Fuses in the battery box p 8 56 Check valves switch on continuous operation For the 3rd axle line Always switch on the continuous opera tion ...

Page 397: ...s in the straight running position Steering of the 4th axle line The valves are labelled The valves are actuated by pressing the valves in the middle 3 with a blunt object Actuate the valve for the required steering direction until the 4th axle line is in the straight running position s G Risk of crushing due to turning wheels Ensure that there are no persons near the wheels being steered before s...

Page 398: ...A Take the nut 3 off of the valve 5 B Fit the magnets 4 pay attention marking Tighten the nut 3 hand tight on the valve 5 Inserting the fuses After emergency operation you must insert the fuses again so that the 5th axle line can be steered while driving Turn off the ignition Insert the fuses F2 4 and F2 5 à Fuses in the driver s cab p 8 50 Insert the fuse F10 à Fuses in the battery box p 8 56 Aft...

Page 399: ...information on tilting Before tilting the driver s cab the following requirements must be met The truck crane must be level All loose objects must be removed from the driver s cab The main boom is raised to the extent about 1 5 m 4 9 ft that the driver s cab will not touch the main boom nor the hose drum when tilting Ensure that the hook block is outside the driver s cab slewing range and the wind...

Page 400: ...and lowered using a hand pump The lever for the hand pump is below the seats or in the tool box Insert the lever 1 into the hand pump 3 To tilt the driver s cab turn the lever 2 forward to position A To lower the driver s cab turn the lever 2 backwards to the B position Before tilting the driver s cab note the prerequisites specified at the begin ning of the section à Prerequisites and information...

Page 401: ... is tilted Close the doors This prevents e g liquids from getting into the instrument panels and doors from swinging open during tilting thereby injuring people G Risk of accidents due to driver s cab tilting When you are tilting the driver s cab forward and while it is actually tilted forward no one may be in front of the driver s cab S Risk of damage when the main boom angle is too small Only ti...

Page 402: ...p 1 the driver s cab is lowered Lower the driver s cab to its end position the lock closes audibly Switch on the ignition and check that the symbol 1 has gone out If necessary lower the driver s cab further until the symbol 1 goes out G 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 G Risk of accide...

Page 403: ...lfunctions in driving mode 8 6 Tilting lowering the driver s cab Operating manual 3 302 709 en 8 47 GMK5150L 12 01 2018 Remove the lever 1 and stow it away safely Close the front flap à Front flap p 3 73 ...

Page 404: ...Malfunctions in driving mode 8 6 Tilting lowering the driver s cab 8 48 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 405: ...ignition whenever a fuse has to be replaced S Risk of damage if the ignition is switched on Switch off the ignition whenever a fuse has to be replaced This prevents the new fuse being blown immediately by the increased starting current after being installed S Risk of damage by overloading Replace blown fuses only with new fuses of the same amperage This pre vents parts being overloaded and damaged...

Page 406: ...signations 1 to 8 in the tables correspond to their order from left to right fuse 1 is always the left fuse Observe the instructions for fuse changes à p 8 49 Designation Amperage A Function F1 1 3 Ignition lock F1 2 15 Control unit UB 2 CCM 11 F1 3 15 Control unit UB 2 CCM 11 F1 4 15 Permanent positive voltage terminal 30 F1 5 5 Engine transmission diagnostics plug F1 6 10 Electronic gear system ...

Page 407: ...rol unit UB 2 IOL 31 F2 5 15 Control unit UB 1 IOL 32 Electronic steering system F2 6 15 Control unit UB 1 IOL 32 F2 7 15 Control unit UB 2 IOL 32 F2 8 15 Control unit UB 2 IOL 32 Designation Amperage A Function F3 1 15 Control unit UB 1 IOL 33 F3 2 15 Control unit UB 1 IOL 33 F3 3 15 Control unit UB 2 IOL 33 F3 4 15 Control unit UB 2 IOL 33 F3 5 10 ABS control unit F3 6 10 ABS control unit F3 7 1...

Page 408: ...4 2 20 Dual tank switchover F4 3 5 CCS display F4 4 Unassigned F4 5 Unassigned F4 6 Unassigned F4 7 Unassigned F4 8 Unassigned Designation Amperage A Function F5 1 20 Auxiliary heater F5 2 3 Control unit UE CCM 11 Control unit UE 2 IOL 31 32 33 F5 3 10 Radio F5 4 5 Tachograph instrument panel F5 5 10 Fan F5 6 Unassigned F5 7 Unassigned F5 8 5 Power supply relay ...

Page 409: ...erse camera Radio F6 4 5 Air intake inhibitor F6 5 10 Gearbox control F6 6 5 Engine transmission diagnostics plug F6 7 3 Outrigger control unit left right Inclination transmitter F6 8 3 Engine electronic control system AdBlue system Designation Amperage A Function F7 1 3 Alternator F7 2 3 Brake circuits 1 and 2 F7 3 3 Auxiliary heater time switch F7 4 15 Retarder F7 5 5 Horn Soot particle filter F...

Page 410: ...ication F8 2 15 Windscreen wiper F8 3 5 Steering coupling F8 4 3 ABS ABS trailer F8 5 10 Horn F8 6 15 Unassigned F8 7 10 Operating the mirror adjustment Window winder F8 8 Unassigned Designation Amperage A Function F9 1 2 Temperature gauge Fuel gauge F9 2 Unassigned F9 3 Unassigned F9 4 Unassigned F9 5 Unassigned F9 6 Unassigned F9 7 Unassigned F9 8 Unassigned ...

Page 411: ...perage A Function F10 1 5 Turn signal indicators Light switch F10 2 10 Rotating beacon carrier superstructure F10 3 5 Parking light Side marker lights Side marker lights front F10 4 3 Instrument lighting F10 5 5 Brake lights Trailer brake lights F10 6 10 Light switch Warning blinkers F10 7 Unassigned F10 8 5 Reversing lamp ...

Page 412: ...compounds on batteries Battery poles battery terminals and parts of the battery itself contain lead and lead compounds Wash your hands after working on these parts or in these areas Designation Amperage A Function F7 50 Driver s cab central fuse F8 25 Battery charger socket F9 25 Superstructure central fuse F10 10 Steer by wire F11 20 Superstructure central fuse F12 25 Driver s cab central fuse F1...

Page 413: ...ed in Chapter 3 9 1 Overview of the operating elements This section shows the position and designations of the operating elements for crane operation This also includes display elements such as lights or displays H Operating elements available only with additional equipment are designated accordingly These designations are made in this section only and are not repeated in the following sections ...

Page 414: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 2 Operating manual GMK5150L 9 1 1 Exterior of the truck crane ...

Page 415: ... Version A4 Key operated switch for overriding the RCL in an emergency RCL override Version B4 No function à p 9 143 à p 9 144 9 Spotlights1 à p 9 8 10 RCL status display à p 11 63 11 Lowering limit switch à p 11 84 12 Hydraulic emergency operation with the hand pump Hydraulic emergency operation acc to BGR 1591 à p 14 51 à p 14 59 13 Counterweight removed à p 12 71 14 Outriggers operation Lightin...

Page 416: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 4 Operating manual GMK5150L ...

Page 417: ...boom pre tensioning1 Switching off boom pre tensioning1 à p 6 14 à p 12 21 25 Reeving and unreeving the hoist rope à p 12 124 26 Hook block Separable hook block1 Hook block with ballast plates1 à p 12 115 à p 12 120 à p 12 122 27 Fuel tank auxiliary heater1 à p 11 5 28 Mirror for crane operation à p 12 150 29 Storage compartment Anemometer Hand held control à p 12 145 à p 12 23 30 Slewing gear ope...

Page 418: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 6 Operating manual GMK5150L 9 1 2 Crane cab ...

Page 419: ...2 9 Adjusting the front panel à p 11 9 10 RCL control unit Rated Capacity Limiter à p 9 76 11 CCS control unit à p 9 16 12 Service brake1 à p 9 162 13 Accelerator pedal 14 Left hand control panel à p 9 12 15 Right hand control panel à p 9 13 16 Handle 17 Crane cab seat Seat contact switch à p 11 8 à p 9 94 18 Rest 19 Ignition lock à p 9 91 20 Cigarette lighter 24 volts 21 Ashtray 22 Slewing gear f...

Page 420: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 8 Operating manual GMK5150L Side panel ...

Page 421: ...n B2 Overriding the RCL in an emergency à p 9 143 à p 9 144 4 Headlight on off à p 9 146 5 Slewable spotlights on off1 à p 9 147 6 Slew slewable spotlight1 à p 9 147 7 RCL override Version A2 Raise enable button after RCL shutdown RCL override Version B2 No function à p 9 121 à p 9 144 8 Windscreen wiper on off à p 9 148 9 Roof window wiper on off à p 9 148 10 Windscreen washing system à p 9 148 1...

Page 422: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 10 Operating manual GMK5150L Crane cab rear ...

Page 423: ...B1 3 4 Loudspeaker1 5 Sockets 12 V à p 9 145 6 Fan with switch1 7 Rear window à p 9 154 8 Cover for Fuses Diagnostics CraneSTAR system1 à p 14 75 à p 9 156 à p 11 158 9 Rest 10 Air vents à p 11 152 11 Fire extinguisher2 12 Air vents à p 11 152 13 Door unlocking mechanism à p 9 155 14 Handle 1 Additional equipment 2 à Maintenance manual 3 à Separate operating manual ...

Page 424: ... p 9 115 4 Auxiliary hoist1 on off à p 11 79 5 Inclining the crane cab à p 9 128 6 Left hand control lever configuration varies depending on the version à p 9 14 7 Dead man s switch à p 9 94 8 Slewing gear freewheel à p 9 118 9 Depending on which function is switched on button for Derricking gear high speed mode Telescoping mechanism high speed mode Steering with separate steering Economy Mode ste...

Page 425: ...oping mechanism on off à p 9 122 5 Lattice extension derricking gear1 2 6 Right hand control lever configuration depends on version à p 9 14 7 Dead man s switch à p 9 94 8 Horn à p 9 149 9 Depending on which function is switched on button for Hoist high speed mode on off Steering in normal steering mode à p 9 114 à p 9 166 10 Main hoist slewing indicator à p 11 78 1 Additional equipment 2 à Lattic...

Page 426: ...ver configurations The current configuration of the control levers is indicated by symbols on the control levers Version 1 In version 1 the left control lever is configured with the Telescope function Left control lever Right control lever 1 Slewing to the left 5 Raising 2 Slewing to the right 6 Lowering the boom 3 Extension 7 Lower the main hoist 4 Retraction of the telescoping 8 Lift the main ho...

Page 427: ...ever is configured with the Telescope function Left control lever Right control lever 1 Slewing to the left 5 Raise retract2 2 Slewing to the right 6 Lower extend2 3 Lower auxiliary hoist1 7 Lower the main hoist 4 Raise auxiliary hoist1 8 Lift the main hoist 1 Additional equipment 2 Derricking the lattice extension à Lattice extension operating manual ...

Page 428: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 16 Operating manual GMK5150L 9 1 5 CCS control unit ...

Page 429: ...h shutdown à p 9 116 6 Sensor for brightness à p 9 98 7 Menu control Select activate confirm à p 9 95 8 Display temperature warning display à p 9 99 9 Service diagnosis connection1 à p 9 156 10 Overview menu groups Operation Overview menu groups Overview à p 9 98 à p 9 22 11 Switch off the RCL buzzer à p 9 98 12 Slewing gear brake engaged released à p 9 119 13 Function only in the menu Outrigger à...

Page 430: ...pendent displays 1 Slewing gear à p 9 118 2 Telescoping mechanism à p 9 122 3 Derricking gear à p 9 120 4 Main hoist à p 9 114 5 Auxiliary hoist1 à p 9 116 6 Lattice extension derricking gear1 2 7 Remote control display3 8 Display time 9 Jog dial display à p 9 98 10 Error display à p 14 8 11 Warning messages display à p 14 3 ...

Page 431: ...ual 9 19 GMK5150L 9 1 7 CCS Start menu s 1 RCL display à p 9 20 2 Engine speed display à p 10 8 3 AdBlue DEF filling level indicator à p 10 8 4 Coolant temperature display à p 10 8 5 Fuel level display à p 10 8 6 Voltage monitoring display à p 10 8 7 Hydraulic oil temperature display à p 10 8 ...

Page 432: ...34 3 Current slewing angle display à p 9 134 4 Maximum permissible speed display Slewing gear à p 9 135 5 Maximum permissible speed display Main hoist à p 9 135 6 Maximum permissible speed display Auxiliary hoist1 à p 9 135 7 Maximum permissible speed display Derricking gear à p 9 135 8 Maximum permissible speed display Telescoping mechanism à p 9 135 9 Slewing range display à p 9 135 1 Additional...

Page 433: ...of current slewing range divisions à p 9 133 1 Slewing range 1 à p 9 133 2 Slewing range 2 à p 9 133 3 Slewing range 3 à p 9 133 4 Slewing range 4 à p 9 133 5 Display of current slewing range limits à p 9 133 6 Current position display à p 9 134 Maximum permissible working radius display à p 9 134 1 1 In slewing range 1 à p 9 134 2 1 In slewing range 2 à p 9 134 3 1 In slewing range 3 à p 9 134 4 ...

Page 434: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 22 Operating manual GMK5150L 9 1 8 CCS Overview menu groups ...

Page 435: ...Telescoping semi automation menu Manual telescoping menu 4 Working range limiter menu group à p 9 47 Overall height menu Working radius menu Slewing angle menu Hoist rope travel limitation menu 5 Information 1 menu group à p 9 52 Hydraulic pressure and fuel consumption menu Datalogger menu Menu opens on the display RCL 6 Heating Engine Additional equipment menu group à p 9 54 Economy menu Remote c...

Page 436: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 24 Operating manual GMK5150L ...

Page 437: ...ontrol lever characteristic curve menu Power unit speeds menu 9 Information 2 menu group à p 9 69 Operating hours menu Engine transmission error menu Crane operation error menu Program version menu Disclaimer menu 10 Various controls à p 9 75 Preheating the hydraulic oil Camera on off Override torque reduction Switching the air traffic control light on and off Switching the rotating beacon on off ...

Page 438: ...ating elements for crane operation 9 1 Overview of the operating elements 9 26 Operating manual GMK5150L 9 1 9 Superstructure menu group 1 Superstructure lock sub menu à p 9 27 2 Counterweight menu à p 9 28 ...

Page 439: ...nterweight menu à p 9 28 2 House lock locking status displays1 à p 9 131 3 Locking status displays à p 9 129 4 House lock on off1 à p 9 131 5 Display switch function for the slewing gear brake à p 9 119 6 Current slewing angle display1 à p 9 130 7 Slewing speed reduction on off à p 9 119 8 Display slewing direction to 0 180 à p 9 130 9 Locking unlocking the turntable1 à p 9 129 1 Additional equipm...

Page 440: ... 2 Display of slewing direction for automatic mode à p 9 110 3 Current slewing angle display à p 9 113 4 Extending Retracting the lifting cylinders à p 9 112 5 Lifting cylinder position display à p 9 112 6 Automatic mode rigging à p 9 111 7 Lifting cylinder position display à p 9 112 8 Automatic mode unrigging à p 9 111 9 Pre tensioning pressure display à p 9 112 ...

Page 441: ...ents for crane operation 9 1 Overview of the operating elements Operating manual 9 29 GMK5150L 9 1 10 Menu group outrigger driving s 1 Outrigger menu Outrigger cylinders menu à p 9 30 à p 9 32 2 Driving menu à p 9 34 ...

Page 442: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 30 Operating manual GMK5150L Outrigger menu ...

Page 443: ...t front left outrigger à p 9 102 5 Pre select front right outrigger display à p 9 102 5 1 Pre select front right outrigger à p 9 102 6 Pre select rear left outrigger display à p 9 102 6 1 Pre select rear left outrigger à p 9 102 7 Pre select rear right outrigger display à p 9 102 7 1 Pre select rear right outrigger à p 9 102 8 Current inclination display à p 9 108 9 exiting the menu à p 9 102 10 S...

Page 444: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 32 Operating manual GMK5150L Outrigger cylinders menu ...

Page 445: ...re select front right outrigger cylinder display à p 9 102 5 1 Pre select front right outrigger cylinder à p 9 102 6 Outrigger pressure display1 à p 12 68 7 Pre select rear left outrigger cylinder display à p 9 102 7 1 Pre select rear left outrigger cylinder à p 9 102 8 Pre select rear right outrigger display à p 9 102 8 1 Pre select rear right outrigger à p 9 102 9 Current inclination display à p...

Page 446: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 34 Operating manual GMK5150L Driving menu l t r ...

Page 447: ...ay Transverse differential locks on off à p 9 161 à p 9 161 11 Longitudinal differential lock display Longitudinal differential lock on off à p 9 161 à p 9 161 12 Supply pressure brake circuits 1 and 2 display à p 9 162 13 Parking brake indicator lamp à p 9 162 14 Display of crane s hydraulic system driving mode on off à p 9 158 15 Steering mode switched on indicator 16 Normal steering mode on roa...

Page 448: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 36 Operating manual GMK5150L Blank page ...

Page 449: ...f the operating elements Operating manual 9 37 GMK5150L 9 1 11 RCL Telescoping menu group s 1 Menu enter rigging mode telescope à p 9 38 2 Lifting capacity tables menu à p 9 44 3 Telescoping semi automation menu à p 9 45 4 Manual telescoping menu à p 9 46 ...

Page 450: ... GMK5150L Menu enter rigging mode telescope For the Standard slewing range type H Depending on the version the top view 2 is shown rotated by 180 The representation occurs in the same manner as in the RCL Monitoring menu à p 9 78 A For the Main boom boom system B For the Lattice extension boom system ...

Page 451: ... the length after the angle1 à p 9 138 7 Lattice extension input angle 1 2 à p 9 138 8 Enter RCL code à p 9 140 9 Angle of the lattice extension display1 2 à p 9 138 10 Enter reeving Main hoist à p 9 137 11 Enter reeving Auxiliary hoist à p 9 137 12 Boom system display à p 9 138 13 Reeving input mode display à p 9 137 14 Counterweight display à p 9 136 15 Accept the measured outrigger span à p 9 1...

Page 452: ...erating elements 9 40 Operating manual GMK5150L For the MAXbase slewing range type 1 H Depending on the version the top view 2 to 5 is shown rotated by 180 The representation occurs in the same manner as in the RCL Monitoring menu à p 9 78 1 Additional equipment ...

Page 453: ...à p 9 139 5 Input rear right outrigger width à p 9 139 2 to 5 Outrigger span monitoring display à p 9 139 6 Enter counterweight à p 9 136 7 Enter reeving Main hoist à p 9 137 8 Enter reeving Auxiliary hoist à p 9 137 9 Reeving input mode display à p 9 137 10 Counterweight display à p 9 136 11 Accept the measured outrigger span à p 9 139 12 Pre selection telescoping menu à p 9 42 13 Preselected tel...

Page 454: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 42 Operating manual GMK5150L Pre selection telescoping menu ...

Page 455: ... boom length à p 9 141 4 Input slewing range1 à p 9 141 Pre selection telescoping 5 Sort values à p 9 141 6 Selectable telescoping display à p 9 141 6 1 Associated maximum load à p 9 141 6 2 Associated maximum working radius à p 9 141 6 3 Associated telescoping duration à p 9 141 6 4 Associated main boom length à p 9 141 7 Overview of the table lengths 1 Display only with the MAXbase slewing range...

Page 456: ...ge type 1 Slewing range display 2 Permissible working range display range under the curve I Main hoist display Limitation due to reeving II Auxiliary hoist display Limitation due to reeving à p 11 59 1 Slewing range display Four slewing ranges marked in colour 2 3 4 5 Permissible working range display A coloured curve for each slewing range I Main hoist display Limitation due to reeving II Auxilia...

Page 457: ...election individual telescopic sections à p 9 125 4 Confirm pre selection à p 9 125 5 Current telescope status display à p 9 124 6 Telescoping permitted display Telescoping not permitted display à p 9 125 7 Locking status telescopic section display à p 9 123 8 Telescoping cylinder length display à p 9 124 9 Locking status telescoping cylinder display à p 9 123 10 Teleautomation direction display à...

Page 458: ...2 Symbol lock release telescopic section à p 9 126 3 Telescoping cylinder in the telescopic section display à p 9 127 4 Locking status telescoping cylinder display à p 9 125 5 Locking releasing the telescoping cylinder à p 9 126 6 Locking point display à p 9 126 7 Telescoping cylinder length display à p 9 126 8 Telescoping direction display à p 9 127 9 Main boom length display à p 9 127 ...

Page 459: ...Overview of the operating elements Operating manual 9 47 GMK5150L 9 1 12 Working range limiter menu group s 1 Overall height menu à p 9 48 2 Working radius menu à p 9 49 3 Slewing angle menu à p 9 50 4 Hoist rope travel limitation menu à p 9 51 ...

Page 460: ...erating manual GMK5150L Overall height menu 1 Switching monitoring function on off à p 11 138 2 Current overall height display Accepting limit value 3 Overall height limit value display Entering limit values manually 4 Overall height limit value display 5 Current overall height display ...

Page 461: ...g manual 9 49 GMK5150L Working radius menu s 1 Switching monitoring function on off à p 11 140 2 Current working radius display 3 Current working radius display Accepting limit value 4 Working radius limit value display 5 Working radius limit value display Entering limit values manually ...

Page 462: ...nu 1 Switching monitoring function on off à p 11 142 2 Current slewing angle display Accepting limit value 3 Slewing angle A limit value display Manually entering limit value 4 Current slewing angle display 5 Slewing angle B display 6 Slewing angle A display 7 Slewing angle B limit value display Manually entering limit value ...

Page 463: ...ual 9 51 GMK5150L Hoist rope travel limitation menu 1 Switching monitoring function on off à p 11 145 2 Raise input confirmation 3 Lower input confirmation 4 Current hoist rope position display 5 Raise limit value display Accepting limit value 6 Lower limit value display Accepting limit value ...

Page 464: ...ne operation 9 1 Overview of the operating elements 9 52 Operating manual GMK5150L 9 1 13 Information 1 menu group 1 Hydraulic pressure and fuel consumption menu à p 9 53 2 Datalogger menu Menu opens on the display RCL à p 9 81 ...

Page 465: ...aulicpressure and fuel consumption menu 1 Angle gear temperature display à p 9 128 2 Hydraulic system pressure display Slewing gear circuit à p 9 128 3 Telescoping cylinder pressure display à p 9 128 4 Hydraulic circuit pressure display à p 9 128 5 Display of consumption in litres per hour1 1 Additional equipment ...

Page 466: ... Overview of the operating elements 9 54 Operating manual GMK5150L 9 1 14 Heating Engine Additional equipment menu group 1 Economy menu à p 9 55 2 Remote control menu à p 9 56 3 Heating air conditioning menu à p 9 57 4 Spotlights menu à p 9 58 ...

Page 467: ...ane operation 9 1 Overview of the operating elements Operating manual 9 55 GMK5150L Economy menu s 1 Switching off Economy mode on off à p 9 92 2 Set interval 1 à p 9 92 3 Set interval 2 à p 9 92 4 Average consumption à p 9 92 ...

Page 468: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 56 Operating manual GMK5150L Remote control menu 11 1 Remote control menu à p 9 132 2 Remote control display à p 9 132 ...

Page 469: ...1 152 3 Setting the temperature à p 11 151 4 Automatic air conditioning system à p 11 154 5 Defrosting the windscreen à p 11 151 6 Setting the fan à p 11 151 7 Air conditioning system on off à p 11 153 8 Cooling maximum à p 11 154 9 Recirculated air à p 11 151 10 Frost Guard1 2 11 Setting the auxiliary heating à p 11 155 12 Heating on display à p 11 151 1 Additional equipment 2 à Separate operatin...

Page 470: ...ew of the operating elements 9 58 Operating manual GMK5150L Spotlights menu 1 Switching automatic spotlights on off à p 9 147 2 Increase the slewing speed à p 9 147 3 Reduce the slewing speed à p 9 147 4 Opening closing the Settings submenu à p 9 147 ...

Page 471: ...eration 9 1 Overview of the operating elements Operating manual 9 59 GMK5150L 9 1 15 Telescoping emergency program menu group s 1 Telescoping emergency program menu à p 9 60 2 Unknown telescoping menu à p 9 62 1 Additional equipment ...

Page 472: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 60 Operating manual GMK5150L Telescoping emergency program menu XXX sec XXXX mm 1 2 XXXX mm ...

Page 473: ...lescoping cylinder display Locking unlocking the telescoping cylinder à p 14 33 5 Locking status telescopic section display Locking unlocking a telescopic section à p 14 33 6 Display position of the telescoping cylinder in the foot section à p 14 33 7 Telescoping cylinder locked Telescopic section unlocked 8 Telescoping cylinder locked Telescopic section locked 9 Telescoping cylinder unlocked Tele...

Page 474: ...access code unknown telescoping à p 14 41 2 Input for telescopic section 1 à p 14 41 3 Input for telescopic section 2 à p 14 41 4 Input for telescopic section 3 à p 14 41 5 Input for telescopic section 4 à p 14 41 6 Input for telescopic section 5 à p 14 41 7 Input confirmation à p 14 41 8 Telescoping permitted not permitted display à p 14 41 ...

Page 475: ...Operating manual 9 63 GMK5150L 9 1 16 Menu group settings s 1 Crane cab menu à p 9 64 2 Set display brightness and date time menu à p 9 65 3 Switch units menu à p 9 66 4 Set control lever characteristic curve menu à p 9 67 5 Power unit speeds menu à p 9 68 1 Additional equipment ...

Page 476: ...al duration selection display à p 9 149 2 Selection display of skylight interval duration à p 9 149 3 Retract extend step selection à p 12 157 4 Retract step à p 12 157 5 Extend step à p 12 157 6 Adjust interval selection à p 9 149 7 Adjust interval display à p 9 149 8 Windscreen selected display à p 9 149 9 Skylight selected display à p 9 149 ...

Page 477: ...This is operated in the same way as in the driver s cab s 1 Selection setting the display brightness à p 4 11 2 Increasing reducing the value à p 4 11 3 Display in percentage à p 4 11 4 Brightness display à p 4 11 5 Adjust time selection à p 5 24 6 Setting the time à p 5 23 7 Increasing reducing the value à p 5 24 8 Switching the display type à p 5 23 ...

Page 478: ...r crane operation 9 1 Overview of the operating elements 9 66 Operating manual GMK5150L Switch units menu 1 Display units in Metres Degrees Celsius Kilograms Bar à p 11 128 2 Display units in Feet Degrees Fahrenheit lbs Psi ...

Page 479: ...racteristic curve menu s 1 Characteristic curve slewing gear à p 11 129 2 Characteristic curve telescoping mechanism 3 Characteristic curve derricking gear 4 Characteristic curve main hoist 5 Auxiliary hoist1 characteristic curve 6 Lattice extension1 characteristic curve 7 Setting Reset characteristic curve 1 Additional equipment ...

Page 480: ... GMK5150L Power unit speeds menu 1 Enter slewing gear speed à p 11 125 2 Enter telescoping mechanism speed 3 Enter derricking gear speed 4 Enter speed main hoist 5 Enter speed auxiliary hoist1 6 Enter speed derricking gear of lattice extension1 7 Reset power unit speed settings 1 Additional equipment ...

Page 481: ...he operating elements Operating manual 9 69 GMK5150L 9 1 17 Information 2 menu group s 1 Operating hours menu à p 9 70 2 Engine transmission error menu à p 9 71 3 Crane operation error menu à p 9 72 4 Program version menu à p 9 73 5 Disclaimer menu à p 9 156 ...

Page 482: ...XXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX n XXXX n XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX n XXXX n 1 Keycode entry and confirmation à p 11 133 2 Slewing gear 3 Telescoping mechanism 4 Derricking gear 5 Main hoist 6 Transmission 7 Engine 8 Locking system 9 Auxiliary hoist 10 Carrier 11 Superstructure 12 Lattice extension luffing jib1 13 Selection all 1 Additional equipment ...

Page 483: ...ements Operating manual 9 71 GMK5150L Engine transmission error menu This is operated in the same way as in the driver s cab s 1 Display of error total errors à p 14 8 2 Engine symbol display 3 Transmission symbol display 4 Error code display 5 Previous error 6 Next error ...

Page 484: ... operation 9 1 Overview of the operating elements 9 72 Operating manual GMK5150L Crane operation error menu 1 Display of error total errors à p 14 8 2 Error message display 3 To acknowledge the error 4 Previous error 5 Next error ...

Page 485: ...Operating elements for crane operation 9 1 Overview of the operating elements Operating manual 9 73 GMK5150L Program version menu 1 Serial number display à p 14 3 2 Program version display à p 14 3 ...

Page 486: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 74 Operating manual GMK5150L Blank page ...

Page 487: ...ts Operating manual 9 75 GMK5150L 9 1 18 Various controls 1 Preheating the hydraulic oil à p 9 128 2 Camera on off à p 12 156 3 Override torque reduction à p 11 132 4 Switching the air traffic control light on and off à p 12 146 5 Switching the rotating beacon on off à p 9 146 ...

Page 488: ...erating manual GMK5150L 9 1 19 RCL control unit 1 RCL display 2 USB connection for data export à p 9 142 3 No function 4 Switch off RCL buzzer à p 9 98 5 RCL early warning à p 11 57 6 Sensor for brightness à p 9 98 7 RCL shutdown à p 11 57 8 Display temperature warning display à p 9 100 ...

Page 489: ...ne operation 9 1 Overview of the operating elements Operating manual 9 77 GMK5150L 9 1 20 Menu independent displays 1 Warning messages display à p 14 10 2 Working range limiter displays à p 11 136 3 RCL status display à p 11 51 ...

Page 490: ... of the operating elements 9 78 Operating manual GMK5150L 9 1 21 RCL menus Monitoring menu H Depending on the version the top view in view A is shown or is shown rotated by 180 in view B This operating manual shows view A in the subsequent illustrations ...

Page 491: ...aximum load display à p 11 51 13 Display of the currently raised load à p 11 50 14 Display of reeving used à p 11 46 15 Status display for current main boom angle à p 11 50 16 Counterweight display à p 11 45 17 Current working radius display à p 11 49 18 Current inclination display à p 9 108 19 Telescoping direction display à p 11 52 20 Current telescope status display à p 11 51 21 Telescoping cyl...

Page 492: ... 9 80 Operating manual GMK5150L Lifting capacity tables menu The same menu is displayed as shown on the CCS display à p 9 44 H Either the Monitoring menu or the Lifting capacity table menu is displayed Additionally the Datalogger menu can be manually opened from the CCS display ...

Page 493: ...nts for crane operation 9 1 Overview of the operating elements Operating manual 9 81 GMK5150L Datalogger menu y 1 Export data à p 9 142 2 Display of export progress à p 9 142 3 USB connection for data export à p 9 142 ...

Page 494: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 82 Operating manual GMK5150L Blank page ...

Page 495: ...ating manual 9 83 GMK5150L 9 1 22 Hand held control H Required connections for the various movements à p 9 150 1 Engine control panel à p 9 151 2 Pre select emergency operation1 à p 9 152 3 Function buttons à p 9 152 4 no function 5 no function 6 Horn à p 9 151 1 Additional equipment ...

Page 496: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 84 Operating manual GMK5150L Blank page ...

Page 497: ...uttons This function of the illustrated buttons is the same in all the menus This function of the other buttons depends on the opened menu s 1 Outrigger display à p 9 103 2 Position lights for indicator lamps à p 9 103 3 Menu selection Outrigger menu Raise axle menu à p 9 103 à p 9 86 à p 9 88 4 START engine à p 12 29 5 Horn à p 9 104 6 STOP engine à p 12 29 ...

Page 498: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 86 Operating manual GMK5150L Outrigger menu ...

Page 499: ...e right outriggers opposite side à p 9 105 4 Operating the right outriggers à p 9 105 5 Additional function F1 6 Retracting all supporting cylinders à p 9 105 7 Extending all supporting cylinders à p 9 105 8 Pre select high speed mode à p 9 103 9 Pre select normal speed Automatic alignment as additional function F1 à p 9 103 à p 9 105 1 1 Left hand outrigger pressure display à p 9 109 2 1 Left han...

Page 500: ...ements 9 88 Operating manual GMK5150L Raise axle menu 1 to 5 Pre selection display à p 9 106 6 Directional indicator 7 Wheel load display opposite à p 9 107 8 Wheel load display operator s side à p 9 107 9 Pre selecting wheels à p 9 106 10 Lifting lowering wheels à p 9 107 ...

Page 501: ... Directions always depend on whether the carrier or the superstructure is being operated On the carrier The driver s cab is always at the front which means that Forwards always means the driver s cab is to the front Backwards always means the rear lights on the carrier are leading On the superstructure The main boom head is always at the front which means that s G Risk of accident by operator erro...

Page 502: ...Symbols can be shown in different colours The colour of the symbol indicates the current switching state of the relevant power unit In these operating instructions we always refer to colours in terms of The symbol is red for instance regardless of whether the background 1 of a symbol is red or whether only parts 2 of a symbol are red This applies to all symbols and all colours If the instruction g...

Page 503: ...Set idling speed The engine is running Left control lever The engine must be off s 0 Ignition off engine off key can be removed 1 Ignition on and power supply on for instrument lighting CCS engine control system RCL à p 10 7 Press upwards once Engine starts idling speed standard Press up Increase idling speed Press down Decrease idling speed engine cutout after about 6 seconds à p 10 9 Press and k...

Page 504: ...ymbol and confirm for 9 2 4 AdBlue system CCS display AdBlue warning Opening Select and confirm symbol 1 1 Switching off Economy mode on off 2 Set interval 1 3 Set interval 2 4 Average consumption à p 11 126 1 Green AdBlue tank level sufficient Yellow Adblue DEF tank almost empty à AdBlue tank p 4 7 Red Adblue DEF tank empty symbol 2 displayed ...

Page 505: ... is started 1 Out Torque reduction off or overridden 2 On Torque reduction on Symbol 2 is displayed 1 Select and confirm Torque reduction overridden for 30 minutes symbol 3 displayed after 30 minutes 1 Select and confirm Torque reduction overridden for 30 minutes symbol 3 displayed after 30 minutes 1 Select and confirm Torque reduction overridden for 30 minutes symbol 3 displayed after this symbol...

Page 506: ...tact switch 2 on or Press at least one dead man s switch 1 Safety function on Get off seat seat contact switch off and Both dead man s switches 1 not pressed All operating elements for crane functions in the crane cab are locked Any crane movements are slowed down to standstill within 3 seconds and then locked Crane cab seat version 2 The seat contact switch is very sensitive It is recommended tha...

Page 507: ...e jog dial or CCS control panel the overview of the menu groups 2 appears A symbol is selected with the jog dial or the selection buttons on the CCS control panel to call up a menu A selected symbol is shown in red A menu is opened by pressing the jog dial or the OK button on the control panel Menu control Buttons for selecting activating and confirming areas on the CCS display Select Activate con...

Page 508: ...a For selecting and confirming values A field 1 with numbers or letters is marked Select a value Confirm value 1 Slewing or 2 Press The next symbol is marked 1 Press or 3 Press The corresponding menu is opened 1 Slewing1 or 2 Press 4 Value can be reduced increased 5 Highest value achieved 6 Lowest value achieved 1 Holding pressed and turning results in a quick value change 1 Press or 3 Press Displ...

Page 509: ...r cylinder 1 For turning on off and switching A symbol for a status is marked e g symbol 2 Executing a movement Select function Move function Turning on off and switching Selecting status Switch on state s 3 Press or 1 Slewing The marked function 4 or 5 is selected 2 Press The selected function is carried out 2 Press or 1 Slewing The marked state 4 or 6 is selected 1 Press or 3 Press The selected ...

Page 510: ...sor for brightness Registers the brightness of the operating environment The brightness of all displays is automatically adjusted à Display setting the brightness p 10 6 Press the button once The opened menu closes the menu from the next higher level is opened Input mode is deactivated 1 Press After the first press Menu groups overview display After a subsequent press Next previous group overview ...

Page 511: ...ups Select A symbol is selected such as symbol 2 Deselect A favourites symbol is selected Serial number and program version display s Blue flashing Temperature too low display will not be switched on Temperature too high Red lights up Brightness is reduced Yellow flashing Display is switched off Red flashing Control unit is switched off à Temperature on the display p 11 31 1 Press The symbol is ma...

Page 512: ...2 56 The display fields must be switched on for crane operation in the driver s cab in the Settings menu on the CCS display Control panels Short description on the CCS display Press Engine off crane functions stop immediately Switch latches Turn the latched switch Switch returns to initial position crane functions released à p 10 12 1 Lifting limit switch warning à p 9 118 2 Slewing gear brake ind...

Page 513: ...firm symbol 1 Red Slewing gear switched off symbol 1 out Green Slewing gear switched on outrigger movement disabled symbol 1 is displayed à p 12 45 Red Suspension is switched off Green Suspension switched on outrigger movement disabled symbol is displayed à p 12 45 Red Parking brake released outrigger movements locked Out Parking brake applied outrigger movements enabled à p 12 45 Switch on Select...

Page 514: ...er An outrigger cylinder or outrigger beam is pre selected The movement stops after the button is released or when an end position is reached Switch on Select symbol 2 and confirm symbol 1 is grey Switch off Select symbol 1 and confirm symbol 2 is grey à p 12 45 1 Exiting the menu 2 Outrigger menu 3 Outrigger cylinders menu Pre selection on Press the required button 1 Pre selection off Release the...

Page 515: ...for indicator lamps Light up when the ignition is on Outrigger display Menu selection Pre select high speed normal speed mode s Display field lighting off Ignition on and no button activated yet or no button activated within the last 10 seconds Display field lighting on Press any button à p 12 51 Display To display the Outrigger and Raise axle menus Some of the buttons under the display can have d...

Page 516: ...t outriggers next to control unit Button 5 or 6 is pressed Movement stops after the button is released and when an end position is reached 1 Press Carrier horn on Opening Press button 2 repeatedly until display 1 appears 1 Retract Press button outrigger beam retracts1 2 Extend Press button outrigger beam extends1 3 Retract Press button outrigger cylinder retracts 4 Extend Press button outrigger cy...

Page 517: ...ending retracting all outrigger cylinders Button 3 or 4 is pressed 1 Retract Press button all outrigger cylinders retract 2 Extend Press button all outrigger cylinders extend Movement stops after the button is released and when an end position is reached à p 12 57 Automatic alignment Press button 1 and button 2 together Truck crane is levelled horizontally The process stops as soon as the truck cr...

Page 518: ...aise axle menu is open Pre selection display Pre selected wheels are black e g all wheels on the operator s side Pre selecting wheels Only pre defined wheel groups can be selected Selectable wheel groups Opening Press button 2 repeatedly until display 1 appears 1 Forwards Press button once next wheel group 2 Back Press button once previous wheel group A All wheel groups All wheels Opposing wheels ...

Page 519: ...s exceeded Wheel load display The displays A to D show the sum of the wheel loads for the associated wheels Opposite the operator side Operator s side The display is in tons or kilopounds depending on the setting 1 Kilopound 1 000 lbs 1 Raise Press the button the selected axles are raised and the truck crane is lowered 2 Lower Press the button the selected axles are lowered and the truck crane is ...

Page 520: ...tching over the measuring range A In the Monitoring menu B In the Outrigger menu C On the Outrigger control units 1 Measuring range display 2 Inclination indicator 3 Directional indicator A In the Monitoring menu B In the Outrigger menu Changeover is automatic the current measurement range 1 is displayed 1 or 5 C On the Outrigger control units Press button 2 once the current measurement range 1 is...

Page 521: ...max maximum permissible reduced wind speed as shown in the Lifting capacity table Unit of measurement Displayed depending on setting t tons or klbs kilopounds 1 kilopound 1 000 lbs Precision One decimal place à p 12 68 Unit of measurement Lights up depending on setting t tons or klbs kilopounds 1 kilopound 1 000 lbs Precision When in t one place of decimals When in klbs no places of decimals à p 1...

Page 522: ...e the following rigging positions are displayed à p 12 104 Display of slewing direction for automatic mode Automatic mode is switched on Opening Select and confirm symbol 1 1 White not in the rigging range 2 Green move the lifting cylinder position 3 Red intermediate position lifting cylinder movements blocked 4 Green lift lower the counterweight position 0 position Arrow is displayed Move control...

Page 523: ...omatically Slewing in Move lifting cylinders position Extend lifting cylinders Move the control lever for slewing gear in indicated direction automatically Slewing in Lift lower counterweight position Lift counterweight Pre tension counterweight Automatic mode ends symbol yellow à p 12 105 Display Yellow Recognition that the counterweight is unrigged Flashing Automatic mode on Grey Automatic mode ...

Page 524: ...ded 2 Green retracted 3 Yellow intermediate position 4 Violet error 5 Extended length in per cent 1 Extend Display 5 and symbol 3 yellow or Display 6 and symbol 4 yellow Select symbol and confirm slewing is disabled after extending 2 Retract Select symbol and confirm after reaching the end position the counterweight is pre tensioned The movement stops after the button is released and when an end p...

Page 525: ...ear House lock menu à p 9 118 Current slewing angle display Identical to the display in the Slewing gear House lock menu à p 9 129 1 Green Slewing enabled if no other shutdown has occurred 2 Red Slewing disabled by counterweight the corresponding warning is displayed The pre tensioning pressure is too low or the counterweight is not completely lifted à Extending retracting the lifting cylinders p ...

Page 526: ...trol lever Hoist high speed mode on off The parking brake is engaged CCS display Power units display Press once Lamp bright main hoist on Lamp dim main hoist off à p 11 76 Back Lifting Forward Lowering à p 11 77 Left High speed mode on off when released Once to the right High speed mode on continuous operation Once to right or once to left High speed mode off à p 11 113 Green Main hoist on Red Mai...

Page 527: ...Lifting Symbol 2 Lowering Red Lowering limit switch triggered main hoist stop Grey Lowering limit switch not triggered à p 11 82 2 Press Shutdown functions of the lifting limit switch bridged Lamp 1 flashes Buzzer tone sounds Enable crane movements move the control lever to the initial position if necessary Slewing gear shutdown bypassed 2 Release Shutdown of the lifting limit switch and shutdown ...

Page 528: ...on off The parking brake is engaged 1 On Lifting limit switch triggered movements which increase the load moment stops 1 Flashing Button 2 pressed 1 Out Lifting limit switch not triggered and not bridged à p 11 82 Press once Lamp bright auxiliary hoist on Lamp dim auxiliary hoist off à p 11 79 Back Lifting Forward Lowering à p 11 80 Left High speed mode on off when released Once to the right High ...

Page 529: ...switch shutdown Warning for lifting limit switch shutdown Overriding the lifting limit switch Green Auxiliary hoist on Red Auxiliary hoist off On High speed mode on Out High speed mode off à p 11 113 Symbol 1 Lifting Symbol 2 Lowering à p 11 113 Red Lowering limit switch triggered auxiliary hoist stop Grey Lowering limit switch not triggered à p 11 82 1 Short description with main hoist à p 9 116 ...

Page 530: ... released Lamp dim slewing gear off Slewing gear brake applied à p 11 116 To the left Slewing to the left To the right Slewing to the right à p 11 117 To switch on Move control lever to zero position and press button slewing gear brake released lamp 1 goes out Switch off Release switch slewing gear brake applied lamp 1 lights up à p 11 119 To switch on Move control lever to zero position and press...

Page 531: ...ng gear off 1 On Slewing gear brake applied 1 Out Slewing gear brake released à p 11 116 To switch Select symbol and confirm the function is displayed 1 Brake pedal function Brake slewing movement actuate Slewing gear brake pedal 2 Control lever function Brake slewing movement control lever in the zero position Slewing gear brake pedal without function à p 11 115 Switch off Select symbol 1 and con...

Page 532: ...g gear telescoping mechanism high speed mode on off The parking brake is engaged Press once Lamp bright derricking gear on power units with the same control lever configuration off Lamp dim derricking gear off à p 11 85 To the left Raise lift main boom To the right Lower lower main boom à p 11 86 Left High speed mode on off when released Once to the right High speed mode on continuous operation On...

Page 533: ...1 GMK5150L CCS display Power units display High speed mode inspection derricking gear Side panel Green Derricking gear on Red Derricking gear off On High speed mode on Out High speed mode off à p 11 113 1 Raise enable button after RCL shutdown RCL override version A à p 9 143 RCL override version B à p 9 144 ...

Page 534: ...amp in the button Control lever The control lever configuration is depends on the version Version 1 Left control lever Version 2 Right control lever Press once Lamp bright telescoping mechanism on power units with the same control lever configuration off Lamp dim telescoping mechanism off à p 11 98 Back Retraction of the telescoping Forward Extension à p 11 98 To the left Retraction of the telesco...

Page 535: ...menu Telescope diagram display Current relation of the telescopic sections to each other section of top view s On High speed mode on Out High speed mode off à p 11 113 Green Telescoping mechanism on Red Telescoping mechanism off Opening Select symbol 1 and confirm menu is opened Locking pin Display 1 and 2 1 On the telescopic section Green Locked 2 On the telescoping cylinder Yellow Intermediate p...

Page 536: ...g cylinder Unit of measurement Displayed in per cent and depending on setting mm millimetres or ft feet à p 11 110 Display Current extended length of the main boom Unit of measurement Displayed depending on setting mm millimetres or ft feet à p 11 110 1 5 Display of telescopic sections 1 to 5 1 5 Display of telescopic sections 1 to 5 1 Pre selection telescoping 0 2 Telescope status 50 pre selectio...

Page 537: ...ylinder locked released s 1 5 Display of telescopic sections 1 to 5 1 Confirm pre selected telescoping 2 Telescoping permitted display 3 Telescoping not permitted display à p 11 110 1 Start telescoping full automation with Retract 2 Start telescoping full automation with Extend à p 11 110 Opening Select symbol 1 and confirm menu is opened Display Yellow Locking pins intermediate position Green Tel...

Page 538: ...cked To unlock Telescopic section locked Select symbol 1 and confirm telescoping cylinder is unlocked à p 11 103 Display Yellow Locking pins intermediate position Green Telescopic section locked Red Telescopic section unlocked To lock The telescoping cylinder is locked Select symbol 2 and confirm telescopic section locked To unlock The telescoping cylinder is locked Select symbol 1 and confirm tel...

Page 539: ...escope diagram display Current relation of the telescopic sections to each other section of top view Display Current extended length of the main boom Unit of measurement Displayed depending on setting mm millimetres or ft feet à p 11 101 1 Extend telescoping cylinder 2 Retract telescoping cylinder 1 Start with Retract 2 Start with Extend à p 11 110 Locking pin Display 1 and 2 1 On the telescopic s...

Page 540: ...t pressure in bar for movements of Preheating the hydraulic oil Press down Incline forward Press up Incline back à p 11 123 1 Angle gear oil temperature 2 Slewing gear 3 Telescoping mechanism 4 Hoist Derricking gear Counterweight hoist unit inclining the crane cab Locking units Switch on Select symbol 1 and confirm symbol is red Switch off Select symbol 1 and confirm symbol is grey à p 11 14 ...

Page 541: ...plays The current position of the locking pin is shown by different symbols Locking unlocking the turntable The superstructure must be in the 0 or 180 position s Opening Select and confirm symbol 1 1 and 7 Red unlocked symbol 8 green 2 and 7 Yellow intermediate position 3 and 7 Violet error 4 and 7 Green locked symbol 8 hidden and 5 Unlocked 6 Locked à p 11 16 To unlock Symbol 1 locking pins retra...

Page 542: ...tional indicator Current position 20 in front of the locking point 0 0 to the rear position locking point 180 180 to the front position locking point 0 1 to 180 0 Turned to the right from 0 0 1 to 179 9 Turned to the left from 0 à p 11 115 Both arrows locking point reached One arrow direction of arrow turning direction towards the locking point à p 11 15 ...

Page 543: ...ock à Switching the houselock on off p 11 17 Locking status displays The current position of the locking pin is shown by different symbols House lock on off 1 Unlocked 2 Intermediate position 3 Blocked locking pin in front of a tooth 4 Locked à p 11 17 Switch on Symbol 1 Pin extends Switch off Symbol 2 Pin retracts à p 11 17 ...

Page 544: ...ntrol menu Remote control display 1 Orange Remote control connected 1 Green Remote control switched on CCS operation from the cab is blocked Symbol 2 is shown green on all menus 1 Off Remote control deactivated Other information à Separate operating manual 1 Green Remote control switched on CCS operation from the cab is blocked Symbol 2 is shown on all menus 1 Off Remote control deactivated Other ...

Page 545: ...or the MAXbase slewing range type Display Slewing ranges working radii Represents the defined slewing ranges and corresponding respective maximum permissible operating radii 5 for the confirmed rigging mode as a diagram Display of current slewing range divisions Shows the currently defined slewing ranges 1 to 4 as pillars 1 to 4 The pillar width represents the angular range Display of current slew...

Page 546: ...ition The display 3 moves a corresponding distance up or down à Slewing range type Standard p 11 53 à Slewing range type MAXbase p 11 55 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 3 White limit region for minimum permissible working radius display only with active l...

Page 547: ...ay p 11 53 Slewing range display The function is identical to the display in the Lifting capacity table menu s 1 Slewing to the left 2 Slewing to the right 3 Lower the main hoist 4 Lift the main hoist 5 Lower the auxiliary hoist 6 Lifting the auxiliary hoist 7 Lowering the boom 8 Raising 9 Extension 10 Retraction of the telescoping 11 Lower the lattice extension 12 Raise the lattice extension Red ...

Page 548: ...e à Enter rigging mode p 11 32 Enter counterweight Counterweight display Select and confirm the symbol 1 the menu opens and opens automatically after Ignition on 1 Display for a slewing range of 360 or for working position1 e g 0 to the front 2 Display for restricted slewing range e g 0 30 After confirmation Menu display 3 1 To accept switch off the slewing gear 4 MAXbase After confirmation Menu d...

Page 549: ... mode select and confirm current reeving 2 Auxiliary hoist functions as with 1 à Enter rigging mode p 11 32 1 Telescope status display in percentage 2 Preselected main boom length 1 in metres m or in feet ft à Enter rigging mode p 11 32 1 Orange Select and confirm Rigging mode and preselected telescope status are adopted lifting capacity table is confirmed Display 2 Monitoring menu on Display 3 St...

Page 550: ...mode select and confirm length Input lattice extension the length after the angle In input mode select and confirm length Lattice extension input angle Only for manually inclinable lattice extensions In input mode select and confirm the angle à Enter rigging mode p 11 32 A Main boom display B Lattice extension display C Heavy load lattice extension display 1 Angle of the lattice extension display ...

Page 551: ...lly for outrigger beams 1 to 4 In input mode select and confirm the individual widths Outrigger span monitoring display MAXbase à Enter rigging mode p 11 32 Enter outrigger span Standard The selection occurs simultaneously for all outrigger beams selected outrigger widths are orange In input mode select and confirm the outrigger span à Enter rigging mode p 11 32 s 5 Measured outrigger width requir...

Page 552: ...ode select and confirm the RCL code The corresponding rigging mode is displayed à p 11 40 A Measured outrigger width required width B Measured outrigger span of required span query menu 2 Required outrigger width for RCL code 1 3 Measured outrigger width 4 Outrigger width not OK for RCL Code 1 red 5 Confirmation Rigged outrigger span outrigger span 2 Crane operation enabled 6 Confirmation Rigged o...

Page 553: ...e telescoping duration the required telescoping times are compared and provided with values between 1 shortest time and 5 longest time Preselect the telescope status select and confirm the desired line e g line 3 The Pre selection telescoping menu closes The Enter rigging mode telescope status menu opens à Pre selecting telescoping p 11 40 s 1 Selection of numerical values 2 Selection by marking t...

Page 554: ...tick is connected to the RCL control unit Starts the data export to the USB stick Display of export progress There are no short descriptions for these displays In the Lifting capacity tables menu à Displaying the lifting capacity tables p 11 59 In the Monitoring menu à Checks before operating the crane p 11 45 à Display during the crane operation p 11 49 Opening Select and confirm symbol 1 1 Conne...

Page 555: ...witch for overriding the RCL in an emergency s 1 Press once RCL shutdown overridden crane functions enabled up to 110 utilisation Crane functions can be started within the next 10 seconds Speed of movements increasing load moment max 15 à RCL override version A p 11 63 1 Press once Release the raise function to the permitted working range If the degree of utilisation is less than 100 release of th...

Page 556: ...ies to RCL programming deviating from EN 13000 For RCL programming in accordance with EN 13000 à p 9 143 Overriding the RCL in an emergency No function No function 1 Press once RCL shutdown overridden crane functions enabled Crane functions can be started within the next 10 seconds Speed of movements increasing load moment max 15 à RCL override version B p 11 67 ...

Page 557: ... Operating manual 9 145 GMK5150L 9 2 23 Electrical system Voltage monitoring warning Sockets 12 V Only connect electrical devices with the matching specification to the socket Display symbol Engine on power failure switch off engine Out Engine on no fault à p 10 8 1 Socket 12 V max 15 A ...

Page 558: ...Switch on Select symbol 1 and confirm symbol ON is displayed Switch off Select symbol 2 and confirm symbol OFF is displayed à p 12 146 Switch on Select symbol 1 and confirm symbol ON is displayed Switch off Select symbol 2 and confirm symbol OFF is displayed Switch on Select symbol 1 and confirm symbol ON is displayed Switch off Select symbol 2 and confirm symbol OFF is displayed à p 12 45 Switch ...

Page 559: ...ts The spotlights are switched on Cab lighting s Switch on Push down lamp in the button on Switch off Push up lamp in the button off à p 11 130 Down Push down Up Push up à p 11 130 1 Switch on symbol 2 display 2 Switch off symbol 1 display 3 Increase the slewing speed 4 Reduce the slewing speed 5 Submenu speed opening closing à p 11 130 1 Always on 2 Always off 3 On off via door contact ...

Page 560: ...stem Windscreen wiper on off Roof window wiper on off Windscreen washing system 1 On 2 Off Off Middle position Interval Push up wiper goes to end position Continuous operation Push down Off Middle position Interval Push up wiper goes to end position Continuous operation Push down Windscreen Push down Skylight Push up No additional wiping function is performed ...

Page 561: ...sting the wiper stroke interval Wiper interval in seconds for à p 11 124 Horn The ignition must be switched on Opening Select symbol 1 and confirm menu is opened 1 Windscreen wiper selection display 5 2 Skylight wiper selection display 6 7 Changing the interval duration 3 Windscreen wiper 4 Roof window wiper 1 Press superstructure horn on ...

Page 562: ...he following applies to all sockets The hand held control is only active when it is connected to the sockets 1 or 2 Pull plug Engine off ignition off Insert plug Switch the ignition on à p 12 23 Enabled operations 1 Emergency operation for crane movements except for telescoping mechanism Derrick lattice extension1 2 Emergency mode for crane operations 1 Additional equipment ...

Page 563: ...nition off 2 CAN monitoring On Hand held control connected no malfunction goes out after 20 seconds Flashing Hand held control connected malfunction 3 Emergency stop switch May only be used in an emergency Press Engine off crane functions stop immediately Switch latches Turn the latched switch Switch returns to initial position crane functions released 4 START engine Press once Engine on 5 STOP en...

Page 564: ...k Pre selected function on Press the required button combination Pre selected function off Release one or both the buttons Press a non assigned button combination pre selection off 1 Main hoist 2 Telescoping mechanism 3 Derrick lattice extension1 4 Auxiliary hoist 5 Derricking gear 6 Slewing gear 1 Lattice extension derricking gear Pre select Press button once lamp 1 lights up pre selection on unt...

Page 565: ...53 GMK5150L à Emergency operation with the hand held control p 14 43 Pre selected power unit Button combination Telescoping mechanism Derricking gear Slewing gear Hoists Lattice extension c e f a b d No Lower No Lowering Lower Retract Raise No Lifting Raise No No Slew to right No No No No Slew to left No No ...

Page 566: ...window The handles on the windscreen and the rear window have the same function Open window A Turn both handles 1 inward Push the window forward Close window B Pull the window closed Turn both handles down pegs 2 located behind the clamp 3 rear window Opening Raise the handle 1 Push window outwards Closing Pull in window Push down the handle 1 ...

Page 567: ...ne cab door From outside Unlocking Turn the key in direction A Locking Turn the key in direction B Open close Pull the handle 1 Slide the door From inside Closing Pull unlocking lever 3 push door forwards by handle 1 engages Locking from inside not possible Opening Pull unlocking lever 2 push door back by handle 1 latches ...

Page 568: ...e connections are present on the CCS and RCL control units 5 Do not connect external devices e g a mobile phone to these connections 9 2 28 Other Disclaimer menu 1 CCS diagnostics serial interface 2 CCS diagnostics CAN bus 3 RCL diagnostics S Risk of damage to the crane control system Do not connect external devices to the diagnostic connections This prevents severe malfunctions in the crane contr...

Page 569: ...ab 9 3 1 Driving menu Driving menu Carrier display s Opening Select symbol 1 and confirm menu is opened The menu is also opened the first time the parking brake is released à p 9 163 Applying The parking brake must be engaged Crane operation mode must be switched on Press button 2 or 3 once menu is closed à p 13 19 1 Display in the front semi circle A 2 Display in the rear semi circle B display of...

Page 570: ...ne operation mode Driving mode must be switched on Select and confirm symbol 2 Symbol 2 white Symbol 1 green Buttons 3 have High speed mode function Transmission in gear 15 Crane s hydraulic system Driving mode off à Selecting the operating mode p 13 19 Display of crane s hydraulic system driving mode on off White Driver s cab Ignition key in position 1 Crane cab Operating elements for driving act...

Page 571: ...e must be stationary Neutral position N Transmission mode D Transmission mode R s Switch on Select and confirm symbol letter is white no gear engaged Switch off Shift to a different gear letter is blue Switch on Select and confirm symbol letter is white Select forwards starting gear Crane s hydraulic system Driving mode off Crane movements disabled Switch off Shift to a different gear letter is bl...

Page 572: ...confirm symbol letter is white Gear 1 forwards on transmission will not shift Crane s hydraulic system Driving mode on Crane movements released Switch off Shift to a different gear letter is blue Switch on Select and confirm symbol letter is white Gear 1 reverse on transmission will not shift Crane s hydraulic system Driving mode on Crane movements released Switch off Shift to a different gear let...

Page 573: ...l differential lock on off A longitudinal differential lock display B transverse differential lock display The current status is shown using different symbols Opening Select symbol 1 and confirm menu is opened Switch on Select symbol 1 and confirm symbol is red Switch off Select symbol 1 and confirm symbol is green Switch on Select symbol 1 and confirm symbol is red Switch off Select symbol 1 and ...

Page 574: ...rier brakes for continuously variable adjustment of the braking force CCS display Supply pressure brake circuits 1 and 2 display Parking brake indicator lamp Side panel from above Parking brake indicator lamp Red Supply pressure less than about 5 bar Green Supply pressure greater than 5 5 bar Red Parking brake applied Grey Parking brake released On Parking brake applied Out Parking brake released ...

Page 575: ...p 1 lights up Parking brake applied Releasing Releasing for the first time after ignition on Press up once Driving menu opens Apply the service brake Wait for about 5 seconds Press up once lamp 1 goes out Parking brake released After the first release Apply the service brake Press up once lamp 1 goes out Parking brake released à After driving p 13 32 Opening Select symbol 1 and confirm menu is ope...

Page 576: ... direction Steering wheel 2 Steering direction Reversed compared to steering wheel To switch over Select desired symbol and confirm The setting will be secured Function Press button 1 to the right wheels turn to the right steering wheel turns to the right Press button 1 to the left wheels turn to the left steering wheel turns to the left Function Press button 1 to the right turn wheels to the left...

Page 577: ...avel mode on off Manual separate steering on off Normal steering mode on road driving on off s Switch on Select symbol 1 and confirm Symbol 2 is displayed Switch off Select a different steering mode symbol 3 à p 13 24 Switch on Select symbol 1 and confirm Symbol 2 is displayed Switch off Select a different steering mode symbol 3 à p 13 24 Switch on Select symbol 1 and confirm Symbol 2 is displayed...

Page 578: ...on 1 Steering in normal steering mode The 2 symbol is displayed 1 Steer 1st and 2nd axle lines with the button 1 To the left 3 and 5th axle lines turn to the left To the right 3 and 5th axle lines turn to the right à p 13 26 To the left 1 and 3rd axle lines turn to the left 3 up to 5th axle lines the matching steering angle for steering mode To the right 1 and 3rd axle lines turn to the right 3 up...

Page 579: ... day Start the engine from the crane cab à p 10 3 Start the engine with the hand held control à p 10 10 10 1 When starting the engine for the first time in the day The first start of the day should always be made from the driver s cab as all the displays for monitoring the engine can only be accessed there Carry out all the required tasks and checks for starting the engine à CHECKLIST Starting the...

Page 580: ... GMK5150L 12 01 2018 When not driving from the crane cab Remove the ignition key If you want to drive from the crane cab Turn the ignition key to position 1 Driving from the crane cab is enabled and the steering lock is prevented from engaging while driving à Preparing to drive p 13 18 H Lock the driver s cab for protection against unauthorised use ...

Page 581: ...1 indicates the current filling level in per cent 100 corresponds to about 400 ltr 105 6 gal 1 The display changes colour depending on the filling level AdBlue The display 1 indicates the current filling level in per cent 100 corresponds to about 40 ltr 10 6 gal The display changes colour depending on the filling level Green Over 10 over 40 ltr 10 6 gal Yellow 5 to 10 20 to 40 ltr 5 3 to 10 6 gal ...

Page 582: ...re inserted into all sockets for the hand held control à p 9 150 Hand held control connected to the superstructure After starting the engine you can use the hand held control to execute all functions which are provided from this socket At the hydraulic tank Before you start the engine all valves on the hydraulic tank must be open The flap is located behind the valve 1 Check that the valve is open ...

Page 583: ...e CCS display shows a menu usually the Enter rigging mode menu Turn the ignition key to position 1 The ignition is switched on The vehicle parking brake must be engaged The lamp 1 lights up symbol 2 red The transmission must be switched to neutral position symbol 1 If the symbol 1 is grey then switch the ignition off and on again After switching on the ignition a lamp test is performed and switchi...

Page 584: ...ocks and the steering are compared Differential locks The state last saved is retrieved In the Driving menu the corresponding sym bols 1 are shown and the electronics system triggers the switching operations Steering When you switch the ignition on the steering is always set to On road driving 2 irrespective of what setting was last saved 10 2 5 Display setting the brightness Open the Settings 1 m...

Page 585: ...rds Let go of the button after the engine starts After starting the idling speed corresponds to the standard value If the engine does not start release the ignition key after about 15 seconds and wait one minute before trying again If the engine does not start after several attempts à Malfunctions on the engine p 8 19 H To set the idling speed à p 10 9 S Danger of explosion when using starter fuel...

Page 586: ...the display area 1 à Malfunctions on the engine p 8 19 Also check the displays The colour of the level indicator indicates within which range the value can be found 1 Engine speed display in rpm 2 AdBlue DEF filling level indicator in per cent 3 Coolant temperature display in C F 4 Fuel level display in percent 5 Voltage monitoring display in volts 6 Hydraulic oil temperature display in C F Green ...

Page 587: ...speed increases continuously until you release the button or the maximum value is reached or Press the button in at the top once The idling speed is increased by one step Reduces the idling speed Push the button 1 down once The idling speed is reduced by one step or Press the button 1 in at the bottom and hold it pressed After about 3 seconds the idling speed will be at the standard value After a ...

Page 588: ...o start the engine if the ignition in the driver s cab or crane cab is switched on Wait until the lamps 1 and 2 light up If the lamp 2 does not light up or flash after about 20 seconds there is a malfunction à p 8 19 Press the 3 button once the engine starts H If the hand held control is connected to the superstructure you cannot drive the power units from the crane cab G Risk of crushing due to t...

Page 589: ...ter switching off Refer to the instructions in the respective sections for each type of stopping work à In case of short work breaks p 11 149 à In case of work breaks of more than 8 hours p 11 150 10 4 2 With the idling button Push the button 1 down and hold it there After about 3 seconds the idling speed will be at the standard value After a further about 3 seconds the engine will switch off the ...

Page 590: ... can restart the engine only after you have reset the emergency stop switch Switch off the ignition Turn the actuated emergency stop switch until it unlatches again If an air intake inhibitor is fitted it must be loosened à Opening the air intake inhibitor p 4 20 G Risk of overloading if used improperly Use the emergency stop switches only in an emergency i e if the crane functions no longer respo...

Page 591: ...ng instructions which are indicated by cross references Observe the warnings and safety instructions there H This checklist only applies to working with a rigged truck crane supported and rigged with counterweight If the truck crane is not yet rigged à CHECKLIST Rigging p 12 1 1 The truck crane has been rigged for the operation to be carried out as described in the CHECKLIST Rigging à p 12 1 2 Ins...

Page 592: ...ary à p 11 130 4 Crane cab heater check the fuel level à p 11 5 5 Earth the load if necessary à p 11 13 6 Adjust crane cab seat and front panel à Crane cab seat p 11 8 à Front control panel p 11 9 7 Start the engine for crane operation à p 10 7 8 Check RCL lifting limit switch seat contact switch and dead man s switch emergency stop switch for correct operation Have faulty units repaired à p 11 10...

Page 593: ...ith the RCL display enter and con firm current rigging mode if necessary à p 11 32 11 Check telescoping à Inspections prior to starting operations p 11 97 12 Switch off the slewing gear for 0 and 180 working positions symbol 1 red à p 11 120 Switch off houselock if fitted for other working positions symbol 2 red à p 11 19 13 Check the electrical system for correct operation à p 11 7 s ...

Page 594: ...k hydraulic oil temperature preheat if necessary à p 11 14 15 Adjust the brightness of the CCS display if necessary à p 10 6 H Additional information on inspections during crane operation on permissi ble working positions and on how to operate the individual power units à Crane operation with main boom p 11 73 ...

Page 595: ...nd seal the tank 1 with the cap Visual inspection Walk around the truck crane and look out in particular for leaking oil fuel or coolant s S Danger of fire due to flammable gases Turn off the engine and heating systems before refuelling G Danger if the crane cannot be unrigged If oil is lost you may no longer be able to move the crane Not even in emergency mode O Risk of environmental damage due t...

Page 596: ...e rope has moved over a complete width X of the rope drum The rope must be evenly wound The rope turns on the drum must be evenly spaced 0 to 2 mm 0 to 0 08 in apart The cross over points must be offset by about 180 H The top rope lines are laid over the next lower rope lines at the cross over points G Risk of crushing due to turning rope drum Keep away from the rope drum while it is turning This ...

Page 597: ...ing manual 3 302 709 en 11 7 GMK5150L 12 01 2018 Checking the electrical system Check the following functions and have faulty parts repaired Working area spotlight Air traffic control light rotating beacons Windscreen wipers windscreen washing system Horn ...

Page 598: ... angle 4 Seat height 5 Seat longitudinal adjustment with control panels 6 Seat longitudinal adjustment without control panels 7 Seat cushion angle 1 Control panel right height 2 Control panel left height 3 Back rest angle 4 Seat heating1 on off 5 Seat height1 6 Seat longitudinal adjustment with control panels 7 Adjust suspension stiffness to body weight 8 Seat longitudinal adjustment without contr...

Page 599: ...2 709 en 11 9 GMK5150L 12 01 2018 Front control panel You can adjust the height and inclination Pull and hold the handle 1 Adjust the front panel to suit your requirements Release the handle 1 In addition the inclination of the display can be adjusted Press either 2 or 3 ...

Page 600: ...l the hook block is lifted off the ground Slowly perform the Raise movement until the hook block lifts the lifting limit switch weight Now check whether the Raise movement is switched off and lamp 1 lights up Check whether the Lower and Extend movements are also switched off The lifting limit switch is working correctly at this point in time if the lamp 1 lights up and the Raise Lower and Extend m...

Page 601: ...the emergency stop switch 3 so that it engages Check whether the engine stops Turn the emergency stop switch until it disengages again Open the air intake inhibitor if required à Air intake inhibitor p 4 20 Repeat the checks with the emergency stop switches 1 and 2 If the emergency off switch is not working correctly do not start work with the crane but notify Manitowoc Crane Care s ...

Page 602: ...o of the right dead man s switch and check whether the crane movement comes to a standstill within about 3 seconds Repeat the check with the dead man s switch on the left control lever Seat contact switch Do not press any dead man s switch 1 Sit down on the crane cab seat and slowly lift the hook block With the control lever actuated stand up and check whether the crane movement comes to a standst...

Page 603: ...ction of at least 16 mm2 0 025 in2 Clamp the other end of the cable 3 to a metal rod 2 with an insulated handle 1 Hold the metal rod firmly by its insulated handle 1 To earth touch the load with the metal rod B Risk of accident due to electric shock Always earth the load before operating the crane Near strong transmitters radio transmitters radio stations etc Near high frequency switchgears If a t...

Page 604: ... 50 F to 32 F You can carry out crane movements with loads only at normal speed at average engine speed and at average operating speed From 0 C to 15 C 32 F to 5 F To preheat only carry out crane movements without a load Only operate at normal speed at medium engine speed and medium working speed Below 15 C 5 F You must preheat the hydraulic oil before carrying out crane movements Prerequisites Th...

Page 605: ...Locking points The locking points are at 0 and at 180 C Open the Superstructure lock menu 1 if necessary The display 1 will show the current superstructure position Slew to locking point at 0 or 180 The display 1 shows positive and negative values For an overview à p 11 118 At the locking point both arrows 2 are shown In the range of 20 around the locking point an arrow 3 indicates the slewing dir...

Page 606: ...contact Manitowoc Crane Care Unlocking the superstructure The RCL shutdown procedure will be triggered and slewing disabled if you unlock the superstructure during a rigging mode for 0 to the rear has been entered To acknowledge the shutdown procedure you must either lock the superstructure or set down the load and enter a rigging mode for a working range of 360 Select the symbol 5 Press the butto...

Page 607: ... to the position in which it is to be locked and then stop the slewing movement Open the Superstructure lock menu 1 if necessary Switching off the slewing gear The slewing gear brake must be engaged when operating the houselock Press the button 1 once The slewing gear will be switched off and the slewing gear brake applied Symbol 2 is red The lamp 3 lights up s S Risk of damage during slewing Alwa...

Page 608: ...rrect the position of the superstructure as follows Select the symbol 6 Press the button until the symbol 1 is displayed Houselock switched off Apply the slewing gear brake Switch on the slewing gear and slew the superstructure a little further minimally Switch off the slewing gear Select the symbol 5 Press the button until the symbol 4 is displayed Houselock switched on If symbol 3 is still shown...

Page 609: ...ewing gear p 11 17 Select the symbol 4 Press the button until the symbol 3 is displayed Houselock switched off The display first shows the symbol 1 then symbol 2 in the intermediate position and then symbol 3 when the houselock is switched off S Risk of damage during slewing Always switch off the slewing gear before you operate the houselock The system will be damaged if the superstructure is slew...

Page 610: ...Crane operation 11 1 Before operating the crane 11 20 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 611: ... rigged outrigger span Slewing with a rigged counterweight is not permitted with all outrigger spans à Slewing with rigged counterweight p 12 113 Working position 0 to the rear Support the truck crane with the outrigger span required according to the Lifting capacity table Slew the superstructure to the rear into the 0 position Lock the turntable à p 11 15 Enter an RCL code for the 0 to the rear w...

Page 612: ...Crane operation 11 2 Standard slewing range type 11 22 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 613: ...ables with different variable outrigger spans are available for the MAXbase slewing range type These additional lifting capacity tables are supplied in digital form with the truck crane and can be shown as a dia gram on the display in the crane cab The designation of the slewing angle always relates to the starting point 0 to the rear A full turn from this working position is divided into two semi...

Page 614: ...cture position is the starting point for the enabled slewing range A com plete turn is always divided in four slewing ranges The size of the slewing range is defined via an angular region around the start ing point e g 60 for the slewing range 1 This results in the enabled slewing range 1 between the slewing angles of 30 to 150 The size of the enabled slewing range depends on the rigged outrigger ...

Page 615: ...applies only to a symmetrical outrigger span with a span of 7 600 m 24 9 ft Smallest individual width 3 350 m 11 0 ft This case applies when one or more outrigger beams is extended to a span of 3 350 m 11 0 ft and all other outrigger beams are extended to larger spans s Positional reference Angular range Enabled slewing range 1 To the right 50 140 to 40 2 Backwards 40 40 to 40 3 To the left 50 40 ...

Page 616: ... individual width 2 550 m 8 4 ft This case applies when one or more outrigger beams is extended to a span of 2 550 m 8 4 ft and all other outrigger beams are extended to larger spans Positional reference Angular range Enabled slewing range 1 To the right 60 150 to 30 2 Backwards 30 30 to 30 3 To the left 60 30 to 150 4 Forwards 30 150 to 150 Positional reference Angular range Enabled slewing range...

Page 617: ...dual width 1 250 m 4 1 ft This case applies when one outrigger beam is extended to a span of 1 250 m 4 1 ft and all other outrigger beams are extended to larger spans Positional reference Angular range Enabled slewing range 1 To the right 85 175 to 5 2 Backwards 5 5 to 5 3 To the left 85 5 to 175 4 Forwards 5 175 to 175 ...

Page 618: ...igger beam retracted left e g for the outrigger span I Outrigger span type Right left Lifting capacity tables are only provided for the combination Right greater than left e g for the outrigger span II When the truck crane is on outrigger beams with a mirrored outrigger span then the same lifting capacities are enabled in the correspondingly mirrored slewing range Example Assuming that the truck c...

Page 619: ...the overload range G Risk of accidents due to an incorrectly set RCL Ensure that the current rigging mode is correctly entered Before starting crane operation An incorrect entry will give you a false sense of security This may result in the truck crane overloading and causing an accident Acquired via measurements Acquired via manual entry Main boom length Main boom angle Current load Lattice exten...

Page 620: ...refer to Manitowoc Crane Care Brightness of the displays The brightness of the CCS and RCL is adjusted automatically Do not cover the sensors 1 and keep them clean to avoid contamination that can affect the brightness adjustment You can set a common minimum brightness for both displays at the CCS control unit This is operated in the same way as in the driver s cab à p 4 11 G Risk of accidents in t...

Page 621: ...that can affect the brightness adjustment After completing the test program The lamps 1 light up All power units are disabled The CCS display shows the last confirmed rigging mode and the RCL display shows the corresponding lifting capacity table The symbol 1 indicates that a rigging mode has not been confirmed If the current rigging mode is displayed then you can conform the rigging mode à p 11 4...

Page 622: ...s slewing ranges and telescopings that are enabled with this rigging mode H You can only change the rigging mode when all crane movements have stopped control lever in the initial position If necessary open the Enter rigging mode telescope status menu 1 on the CCS display The RCL display shows the Lifting capacity table menu The CCS shows the Enter rigging mode telescope status for the last riggin...

Page 623: ... components In the case of individual components the outriggers are always entered as complete outrigger span In the case of individual components the slewing range is entered according to the Lifting capacity table H An overview of all enabled Standard outrigger spans is provided in the section Outriggers à Supplied operating manual Slewing range type MAXbase The MAXbase tables apply which are on...

Page 624: ...components à p 11 34 For the MAXbase slewing range type Select and confirm the display 1 Select and confirm the symbol 2 After confirming the menu 3 is displayed for further rigging mode entry Enter the rigging mode à p 11 34 Entering individ ual components Only enabled rigging modes can be selected For this reason the selection possibilities for the individual components are based on the already ...

Page 625: ...wing range 2 for example working position 0 to the rear Confirm the selection The corresponding RCL code 3 is displayed You can only confirm rigging modes for slewing ranges other than 360 When the selected working position is reached and the slewing gear is switched off When the superstructure is in the selected slewing range If necessary first enter the 360 slewing range and slew the superstruct...

Page 626: ...ent display 1 At the same time the current telescoping is adopted and shown on the display 3 Always check that the currently rigged out rigger span is displayed before confirming the rigging mode Enter outrigger span Standard Select and confirm the display 1 Select the rigged outrigger span for example symbol 2 for 8 030 x 5 900 m 26 3 x 22 0 ft Confirm the selection The selection and the correspo...

Page 627: ...essary you must re enter the outrigger widths in the sequence 1 to 4 Select and confirm the display 1 for the desired outrigger beam Select the rigged individual width 2 e g 5 100 m 12 5 ft Confirm the selection If the outrigger span measured by the outrig ger width monitoring differs from the entered value then the value 3 is displayed in red The symbol 4 becomes grey the rigging mode cannot be a...

Page 628: ...dard slewing range type only Select and confirm the display 1 Select the symbol for the rigged boom system Confirm the selection When selecting Lattice extension additional displays 4 to 6 are shown selection and confirmation is performed in the same manner as with display 1 Display 4 Select an confirm the current length Z before the angle Display 5 Select an confirm the current length Y after the...

Page 629: ...1 2018 The confirmed boom system 1 or 2 is displayed Reeving A Select and confirm the display for the hoist to be used for lifting the load for example display 1 for the main hoist symbol 3 is orange B Select the currently rigged reeving 2 e g 8 fall Confirm the selection and leave the display 1 symbol 3 grey s ...

Page 630: ...t the necessary RCL code 3 e g 1100 Confirm the selection The other displays will show the correspond ing rigging mode 11 4 3 Pre selecting telescoping First enter the current rigging mode Select and confirm the symbol 1 The Pre selection telescoping menu opens Enter the desired parameter 2 à p 9 42 The table shows all permissible telescop ings 4 and the associated parameter 3 for the entered rigg...

Page 631: ...ng modes if necessary The displayed lifting capacity table 9 applies to the RCL code 5 in the corresponding slew ing range 8 and for the preselected telescope status 7 If the actual rigging mode is displayed cor rectly and the planned operation can be per formed within the displayed working range 8 then you can confirm the rigging mode s G Risk of accidents due to an incorrectly set RCL If the cur...

Page 632: ...ing the crane p 11 45 If a deviation in the outrigger span is detected A query menu opens The display 2 shows the outrigger span corresponding to the RCL code 1 The display 3 shows the acquired outrigger span deviating outrigger widths 4 are red Check the currently rigged outrigger span If an incorrect outrigger span is rigged Select and confirm the symbol 5 the menu closes and the rigging mode is...

Page 633: ...n you can confirm the rigging mode s S Risk of accident due to incorrectly supported truck crane A shutdown is not initiated as standard when an outrigger span monitoring error message is issued When an error message is displayed compare the rigged outrigger span with the required outrigger span and rig the required outrigger span This prevents the truck crane from tilting due to an inadequate out...

Page 634: ... RCL display shows the Monitoring menu The CCS display shows the Start menu The crane movements are released if there is no error à Checks before operating the crane p 11 45 If a deviation in the outrigger span is detected The symbol 2 is grey The rigging mode cannot be conformed crane operation is not enabled If the value for an outrigger width is red then a deviating outrigger span has been dete...

Page 635: ...if necessary Display RCL code For the Standard slewing range type only Shows the RCL code corresponding to the confirmed rigging mode according to the Lifting capacity table Outrigger span display Numerical values show the individual widths of the outrigger beams for the confirmed rigging mode in metres m or feet ft Visual display shows the required outrigger span in orange For the Standard slewin...

Page 636: ...ttice extension after the angle according to the confirmed rigging mode in metres m or feet ft Angle of the lattice extension display Only for manually inclinable lattice extensions Shows the required angle of the lattice extension for the confirmed rigging mode Display of reeving used A main boom B Swing away lattice extension1 boom extension1 C Heavy load lattice extension 1 1 For the Standard s...

Page 637: ...Switching over the display A Switch off both hoists both symbols become grey B Switch on the hoist with which you wish to lift the load The corresponding symbol becomes orange for example the symbol 1 for the main hoist If you wish to also lift a load with the other hoist during subsequent crane operation then you must first switch over the display appropriately G Risk of accidents due to incorrec...

Page 638: ...Crane operation 11 4 Operation of the rated capacity limiter 11 48 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 639: ...ength in metres m or feet ft Current working radius display Shows the current working radius horizontal distance between the turnta ble axis and hook block axis in metres m or feet ft The displayed value is calculated on the basis of the telescoping and the main boom or lattice extension angle Current overall height display Overall height vertical distance between the lower edge of the outrigger p...

Page 640: ...in degrees Current slewing angle display Shows the angle of the current superstructure position 180 means that the superstructure is slewed to the front 0 means that the superstructure is slewed to the rear A full turn from this working position is divided into two semi circles When slewing clockwise the slewing angle is displayed as a positive value 0 to 180 0 When slewing anticlockwise the slewi...

Page 641: ...he weight of the current load as a percentage of the maximum possible load degree of utilisation 100 x current load maximum load The display has three coloured regions Depending on the equipment the degree of utilisation is shown on a display 4 with coloured lamps RCL status display The green yellow and red displays 1 are identical to the status displays 2 on the outside of the truck crane Current...

Page 642: ...e display is only active when telescoping with teleautomation and shows the direction in which you must move the control lever for each respective telescoping direction Current wind speed display Shows the current wind speed in metres per second m sec or miles per hour mph The display flashes in colour in the vicinity of the maximum permissible value vmax 1 Start with Retract 2 Start with Extend à...

Page 643: ...r example 30 m 100 ft The current position of the boom head is shown using the symbol 4 and defined by two displays The shutdown range for the maximum working radius 2 is shown in colour and if active the shutdown range for the minimum working radius 6 is displayed When telescoping or derricking The displays 2 move up and down to show the current working radius e g 25 m 20 ft In a shutdown range 1...

Page 644: ...s 2 and 4 remain at the cur rent position The diagram 1 and the dis plays 3 move to the left or right Immediate before the slewing range limits 3 the movement leading towards a shutdown limit is continuously reduced until reaching a standstill The corresponding display 5 shows the current speed reduction e g for slewing to the right Working position The diagram 1 shows the working range e g 0 to t...

Page 645: ...the definition for the slewing angle display 0 to the rear the slewing range limits would be 30 30 150 and 150 The RCL display shows an angular range of approx 200 The range of the diagram is always in the middle corresponding to the current slewing angle 6 for example the range 3 for 120 When slewing The displays 2 3 and 6 remain at the current position The diagram 4 and the displays 5 move to th...

Page 646: ...ner as with the Standard slewing range type à p 11 54 Special case disabled range A slewing range can be disabled in certain cases If for example an outrigger span 1 is rigged and operations are to be performed at the right side with large counterweight combina tions a small working radius and a small load it is possible for the stability towards the rear to become endangered within the slewing ra...

Page 647: ...u can switch off the buzzer tone using button 3 or 4 The lamp 2 lights up The display 1 is in the yellow range H If the current crane continues to move in the same direction there will be an RCL shutdown 11 4 8 RCL shutdown There are different types of RCL shutdowns shutdown due to overload Shutdown due to an error à p 14 8 Shutdown due to working range limiter à p 11 147 Shutdown due to overload ...

Page 648: ...er tone if necessary Leave the shutdown range by moving the crane according to the following table H The crane movements are released when you have left the shutdown area lamps 1 and 2 go out Switched off crane movements Permitted crane movements Lift loads Lower loads Lower the main boom Raising the main boom1 Extend the main boom Retracting the main boom1 Slewing to the left Slewing to the right...

Page 649: ...unit once the Start menu opens Slewing range type Standard If the MAXbase slewing range type has been entered à p 11 61 Permissible working range display The curve 3 applies to the displayed RCL code and the displayed telescope status The working range ends at the maximum pos sible working radius 2 Reduction of the working radius increases the enabled load along the curve 3 up to the maximum possi...

Page 650: ...does not move The symbol 2 for the carrier rotates to the position corresponding to the slewing angle Examples I Display for main hoist for example maximum load 12 t II Display for main hoist for example maximum load 18 t 1 Coloured Enabled slewing range 2 Yellow red Shutdown range for maximum working radius 3 White Shutdown range for minimum working radius display only when the lifting capacity t...

Page 651: ...e colour e g the curve 3 The working range in slewing range 1 ends at the maximum possible working radius 4 Reduction of the working radius increases the enabled load along the curve 3 up to the maxi mum possible load 2 There has to be enough reeving for this load The speed reduction due to reeving occurs in the same manner as with the Standard slewing range type à p 11 60 s 1 Slewing range displa...

Page 652: ... symbol 2 for the carrier rotates together with the display of the slewing range division to the position corresponding to the slewing angle Examples 1 Coloured Enabled slewing range for example blue 2 Yellow red Shutdown range for maximum working radius 3 White Shutdown range for minimum working radius display only when the lifting capacity table specifies a limitation A Current slewing angle 0 B...

Page 653: ...ork à When rigging p 11 64 You can release the raise boom function to leave the shutdown area à To raise the boom p 11 65 In an emergency you can override the RCL shutdown completely à In emergencies p 11 66 Overview status display The lamps 5 to 7 of the status display 4 light up or flash depending on the RCL degree of utilisation and button confirmations s Switch pressed Degree of utilisation 0 ...

Page 654: ... Now a degree of utilisation of up to 110 is enabled If you do not trigger a control lever move ment within 10 seconds after the override you must press the button 1 again The speed of the movements which increase the load moment is reduced to 15 Cancelling the override The override will be cancelled when you press button 1 again or do not activate the control lever for 10 seconds or switch off th...

Page 655: ...on 1 once the information message 2 is displayed Raising is enabled The speed is reduced to 50 Raise the main boom until the degree of utilisation is less than 100 The crane movements will then be ena bled again The button 1 has no function H The raising of the main boom will be shut down if the main boom angle is too great Then all you can do is set the load down Switch off function For degree of...

Page 656: ...e cancelled when you Switch off the ignition Press the key operated switch again The override will automatically be cancelled 30 minutes after the key operated switch has been pressed G 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 t...

Page 657: ...crane movements are enabled If you do not trigger a control lever move ment within 10 seconds after the override you must press the button 1 again The speed of the movements which increase the load moment is reduced to 15 Cancelling the override The override will be cancelled when you press button 1 again or do not activate the control lever for 10 seconds or switch off the ignition G Risk of acci...

Page 658: ...0 FAT32 file system approx 500 MB free capacity is recommended Export data Plug the USB stick into the connection 3 on the RCL control unit The symbol 1 is activated Select and confirm the symbol 1 The display 2 shows the export progress All exported files are named with the serial number start time and end time Files with various different suffixes are exported xxx mcd Contains all exported data ...

Page 659: ... window with various settings is displayed Confirm the selection via the symbol 6 the display 5 shows the import progress A graphical selection window opens If you do not wish to select a graph you can simply close the window symbol 1 à Displaying tables p 11 71 s 1 Import the data is imported for display in the program 2 Convert the data is saved in a log file that can be opened for example with ...

Page 660: ...ents and actuates switches are shown as narrow framed bars 3 Errors are shown as symbols 4 The legend 5 defines the assignments of the colours and symbols You can hide and reveal symbols in the graphic by clicking in the legend Clicking with the left mouse button provides more details 6 on an element Use the symbol 1 to open the graphic selection window 1 Crane use offers the greatest variety of i...

Page 661: ...When the Crane use graphic is also open an element is displayed and marked in the respective other window when clicked Display the error list Select the symbol 2 a table showing all imported errors is displayed Other Select the command 1 for further information 2 List with all lifts 3 List with all events 4 List with all actuated switches 1 Graphical marking 2 Tabular marking ...

Page 662: ...Crane operation 11 4 Operation of the rated capacity limiter 11 72 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 663: ...the 0 or 180 position you must immediately determine the cause and eliminate it and if necessary realign the crane Observe the position of the superstructure when doing so à Levelling the truck crane on outriggers horizontally p 12 60 Safe distances During crane operation always ensure that the truck crane and the load are at a sufficiently large distance to objects and persons Pay particular atte...

Page 664: ... available or in the event of a fault you can find out which speeds are forecast by contacting the relevant weather stations The Lifting capacity table contains an overview of the wind strengths wind speeds and their effects If the maximum permissible wind speed is exceeded No automatic shutdown occurs if the maximum permissible wind speed is exceeded Immediately stop crane operation Put the truck...

Page 665: ... switch off point of the lowering limit switch shifts in the course of the Raise movement The lowering limit switch will lose its function as a safety device G Risk of accidents when raising loads at an angle Loads can cause the main boom to bend resulting in the hoist rope no longer being aligned in a vertical position Compensate for the bend by lowering the boom so that the load will be lifted v...

Page 666: ...ng buttons will light up only dimly Check whether the auxiliary hoist is switched off and therefore secured against unintentional operation The lamp in button 1 should light up only dimly Symbol 2 must be red Press the button 1 once The lamp in button 1 will light up brightly Symbol 2 is green when the main hoist is switched on Check that the current reeving of the main hoist is displayed for exam...

Page 667: ...her speed à p 11 113 You can set the desired engine speed idling speed with button 1 à p 10 9 s G Risk of accidents due to gaps in monitoring Operation of the hoist will only be monitored fully if The lifting limit switch is correctly installed à p 12 139 The lifting limit switch is not overridden à p 11 82 The lowering limit switch is correctly set à p 11 82 G Risk of accident by suspended loads ...

Page 668: ...eeving The scale of the limitation is specified in the supplied lifting capacity table The current speed reduction is displayed in the start menu à p 9 19 You can limit the maximum telescoping speed in the Power unit speed menu à p 11 125 Switching off the main hoist If you no longer require the main hoist you should switch it off to avoid unintentional use Press the button 1 once The lamp in the ...

Page 669: ...d Press the button 1 once The lamp in button 1 will light up brightly Symbol 2 is green when the auxiliary hoist is switched on s G Risk of accidents when operating the auxiliary hoist Read and observe all of the safety instructions in the section titled Main hoist p 11 75 before operating the auxiliary hoist All safety instructions for the operation of the main hoist also apply to the auxiliary h...

Page 670: ...l lever and changing the engine speed with the accelerator You can switch on high speed mode for a higher speed à p 11 113 G Risk of accidents due to gaps in monitoring Operation of the hoist will only be monitored fully if The lifting limit switch is correctly rigged à p 12 139 The lifting limit switch is not overridden à p 11 82 The lowering limit switch is correctly set à p 11 82 G Risk of acci...

Page 671: ...on of the lifting capacity and reeving The scale of the limitation is specified in the supplied Lifting capacity table The current speed reduction is displayed in the start menu à p 9 19 You can limit the maximum telescoping speed in the Power unit speed menu à p 11 125 Switching off the auxiliary hoist If the auxiliary hoist is not required it should be switched off to avoid unintentional use Pre...

Page 672: ...the lifting limit switch weight is not attached The lifting limit switch will not trigger if it is locked The lamp 1 will light up if the lifting limit switch has been triggered At the same time all movements which would increase the load moment will be switched off Lifting Lowering Extending and Derricking the lattice extension if necessary To cancel the shutdown leave the shutdown range by perfo...

Page 673: ...ridden You may override the lifting limit switch only if this is specified in the operating instructions for carrying out maintenance or rigging work With the lifting limit switch overridden you may drive only at the minimum speed and without a load G Risk of accidents due to gaps in monitoring If the lifting limit switch is overridden crane operation is no longer com pletely monitored When hoisti...

Page 674: ...hat the lowering limit switch is set correctly and always complete the lowering operation before the lowering limit switch is triggered This prevents the hoist rope becoming damaged due to complete unreeling or switching off at high speeds and the load being dropped as a result G Risk of accidents due to adjustments made to the lowering limit switch Always re adjust the lowering limit switch if yo...

Page 675: ...if the load lifted is too heavy You can have the operating hours of the derricking gear displayed à p 11 133 Switching on the derricking gear After the ignition is switched on all of the power units will be switched off and the lamps in the corresponding buttons will light up only dimly Press the button 1 once The lamp in button 1 will light up brightly Symbol 2 will be green if the derricking gea...

Page 676: ...hen the main boom is being set down a symbol 1 is displayed Correct the position of the slewable spotlights until the symbol 1 goes out à p 11 130 You can switch on high speed mode for a higher speed à p 11 113 G Risk of accident due to unexpected crane movements If assigned more than one function check whether the Derricking control lever function is switched on before you move the control lever ...

Page 677: ...nt speed reduction is displayed in the start menu à p 9 19 You can limit the maximum derricking speed in the Power unit speed menu à p 11 125 Re enable raising function For RCL override version A If the RCL has switched off the raising function due to an overload you can re enable the raising function with button 1 The speed will then be reduced to 50 Press the 1 button down once Use the control l...

Page 678: ...ion The main boom can be set down by referring to the working curves within the working range specified in the Lifting capacity tables This section supplements the information 1 in the Lifting capacity tables supplied for the main boom intermediate lengths To prevent any overloading of the derricking cylinder the derricking cylinder pressure is also monitored here In area Z of the main boom interm...

Page 679: ...h pre selection When telescoping with pre selection you can enter several parameters for lifting the load and the CCS suggests corresponding telescopings that you can use as the starting point for semi automatic teleautomation Telescoping with pre selection has no independently selectable menu The parameters are entered when entering the rigging mode at the RCL and the telescope status displays ar...

Page 680: ...Crane operation 11 5 Crane operation with main boom 11 90 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 681: ...king pins 7 are pushed into the cutouts 4 of the telescopic section above at the locking points the telescopic section is locked The telescoping cylinder is attached to the basic section 9 with the piston rod 8 The telescoping cylinder has two locking pins 5 at the bottom and a mechanism at the top 10 When the telescoping cylinder is positioned at a locking point The locking pins 5 can be extended...

Page 682: ...a telescoping process Telescoping processes consist of 4 steps 1 unlocking the telescoping cylinder The locking pins 5 retract the telescoping cylinder is unlocked 2 Moving and locking the telescoping cylinder The telescoping cylinder moves into the sec tion to be telescoped for example telescopic section III 3 The locking pins 5 extend the telescoping cylinder is locked ...

Page 683: ... is unlocked 4 Telescoping locking and setting down a telescopic section The telescoping cylinder pushes the telescopic section to a locking point The weight is taken off the mechanism 10 The locking pins 7 extend into the cutouts 4 The telescopic section is automatically set down The telescoping cylinder retracts until the locking pins 7 are positioned on the above telescopic section 1 The weight...

Page 684: ... display The CCS display shows a sectional view of the main boom in the menus 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 6 Cutouts external 7 Cutouts internal ...

Page 685: ...capacities A main boom fixed length is reached if All telescopic sections are locked to a fixed length All telescopic sections are set down Main boom intermediate length A main boom intermediate length is reached if not all telescopic sections are locked to fixed lengths Extend the main boom to the required length before hoisting the load You cannot telescope the boom with the specified lifting ca...

Page 686: ...escoping sequence The telescopic sections can only be telescoped individually one after the other When extending the telescopic section 1 to 6 with the highest number must always be extended first then the telescopic section with the next lower number and so on e g IV III II I The telescopic sections are always retracted in the reverse order of extending A The locking pins 1 are green Each telesco...

Page 687: ...ror message à Malfunctions in the telescoping mechanism p 14 19 If a malfunction results in values being deleted CCS can no longer calculate the current telescoping and will not issue an error message Before the first telescoping compare the telescoping indicated on the CCS display with the current telescoping You must enter the current telescoping if the current telescoping is not displayed corre...

Page 688: ...r Before telescoping a number of prerequisites need to be fulfilled as well Before manual telescoping à p 11 101 Before telescoping with teleautomation à p 11 110 You can adjust the sensitivity of the control levers to suit the operating conditions à Setting the characteristic curves for the control levers p 11 129 G Risk of accident due to unexpected crane movements In the case of multiple config...

Page 689: ...tion With telescoping assigned to the right hand lever With telescoping assigned to the left hand lever Telescoping will only start if arrow 1 or 2 for the selected telescoping direction is green You can regulate the speed by moving the control lever and changing the engine speed with the accelerator H With certain telescoping states the RCL will switch telescoping off for example when you leave t...

Page 690: ...eds menu à p 11 125 Switching off the telescoping mechanism If the telescoping mechanism is not required it should be switched off to avoid unintentional use Press the button 1 once The lamp in the button 1 will light up dimly The symbol 2 red if the telescoping mechanism is switched off If the control lever is assigned more than one function the derricking gear will also be switched off if you sw...

Page 691: ...escoping cylinder à p 11 106 Unlocking the telescopic section à p 11 107 Telescoping the telescopic section à p 11 108 Locking the telescopic section à p 11 109 H The operating order depends on the current initial position For an overview of a telescoping process example à p 11 92 H The lengths given in the following illustrations are purely sample values and may differ from the current display Ch...

Page 692: ... boom length The display 3 shows the corresponding telescopic section for example telescopic section 3 Position of the telescoping cylinder The display 1 shows how far the telescoping cylinder is extended for example 98 If the telescoping cylinder is near a locking point The display 3 shows the corresponding telescopic section for example telescopic section 3 The display 2 shows one or two arrows ...

Page 693: ... tel escoping cylinder Unlocking the telescoping cylinder is required for the telescoping cylinder to be moved separately without telescopic section The telescoping cylinder and the telescopic section cannot be unlocked simultaneously Prerequisites Telescoping mechanism on symbol 3 green Telescoping cylinder locked symbol 2 green Telescopic section locked symbol 1 green s 1 On the telescopic secti...

Page 694: ... 5 Crane operation with main boom 11 104 3 302 709 en Operating manual GMK5150L 12 01 2018 Unlocking Select and confirm the symbol 1 The locking pins 2 retract Yellow Intermediate position Red Unlocked symbol 3 displayed ...

Page 695: ...mbol 1 green Telescoping cylinder unlocked symbol 2 red Extending retracting Move the control lever in the corresponding telescoping direction The telescoping cylinder 2 extends retracts The display 1 shows the currently extended length for example 80 Near a locking point the symbols 3 show The direction of travel to the locking point s Extend Extension Retract Retraction of the telescoping 1 Exte...

Page 696: ... Telescoping mechanism on symbol 3 green Telescopic section locked symbol 1 green Telescoping cylinder unlocked symbol 2 red Locking Move the telescoping cylinder to the desired locking point e g to telescopic section 1 Wait until the display shows the desired telescopic section 1 and the symbols 4 are shown Select and confirm the symbol 3 The locking pins 2 extend S Risk of damage to the boom sys...

Page 697: ...copic section cannot be unlocked simultaneously Prerequisites Telescoping mechanism on symbol 3 green Telescopic section locked symbol 1 green Telescoping cylinder locked symbol 2 green Unlocking Select and confirm the symbol 1 The locking pins 2 retract If symbol 2 is not red after about 10 seconds this means that the locking pins are under load To relieve the load carefully retract and extend a ...

Page 698: ...ism on symbol 3 green Telescoping cylinder locked symbol 2 green Telescopic section unlocked symbol 1 red Telescoping If the requirements for telescoping are met the symbol 3 flashes Move the control lever in the desired tele scoping direction The display 1 shows the current extended length telescoping in metres The current telescope diagram on the display 2 will change continually S Risk of damag...

Page 699: ... à p 11 95 Prerequisites Telescoping mechanism on symbol 3 green Telescopic section unlocked symbol 1 red Telescoping cylinder locked symbol 2 green Locking Telescope to the desired fixed length e g telescopic section 1 1 to 100 If the symbol 4 is displayed the telescopic section must be locked Select and confirm the symbol 3 The locking pins 2 extend s Yellow Intermediate position Green Locked sy...

Page 700: ...escoping cylinder à p 11 106 Telescoping with semi automaton When telescoping with semi automation you enter the desired fixed lengths and then move the control lever in the required direction Switching between the telescopic sections is carried out automatically by CCS H If the desired telescoping status is not a fixed length you can first telescope to the next closest fixed length with the semi ...

Page 701: ...reached symbol 1 go out Move the control lever to its initial position teleautomation off Cancel telescoping semi automation Release the control lever If the telescopic sections are at a fixed length the current telescoping can be entered as the telescoping destination The display 7 shows the current telescoping Enter the current telescoping 1 to 5 and confirm the selection with 6 s 2 Extension 3 ...

Page 702: ...ameters can be entered for the loading case The table shows all permissible telescop ings 6 and the associated parameter 7 for the entered rigging mode A preselected telescope status 8 is shown on the display 9 after confirmation After confirming the rigging mode the display 1 in the Monitoring menu shows the pre selection Telescoping Switch on the telescoping mechanism Move the control lever for ...

Page 703: ...h speed mode will be enabled until you press the button again The symbol 1 indicates the current status H When lowering the boom high speed mode only supports the start of the derricking procedure from steep boom positions It does not increase the derricking speed High speed mode is disabled for raising when performing operations with the lattice extension Hoists High speed mode is always switched...

Page 704: ... of accidents due to overloading Make sure the lifted load is no more than 50 of the maximum load accord ing to the Lifting capacity table maximum degree of utilisation of 50 before operating the hoists in high speed mode S Danger of slack rope with a lightweight hook block If you switch on high speed mode at high speeds a light hook block will not be able to keep the hoist rope taut if it is hois...

Page 705: ...f 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 Correct the rigging mode if necessary à Slewing with rigged counterweight p 12 113 G Risk of accidents due to switched off operating elements Always check that the slewing gear brake function is switche...

Page 706: ...edge the shutdown you must either switch off the slewing gear or set down the load and enter an rigging mode for the 360 working range Releasing the slewing gear brake With the Brake pedal function The slewing gear brake is released when you switch on the slewing gear With the Control lever function The slewing gear brake is released as soon as you move the control lever 2 Lamp 1 will extinguish i...

Page 707: ... set RCL Before slewing always check that the current rigging mode is shown on the RCL display This prevents slewing operations being enabled within the impermissible ranges which would cause the truck crane to overturn G Risk of crushing during slewing Before slewing operate the horn and ensure there are no persons in the slewing range This prevents persons being crushed between the superstructur...

Page 708: ...in the Start menu and in the Superstructure lock menu 0 means that the superstructure is slewed to the rear Angles in the right semi circle are displayed as positive values 0 to 180 Angles in the left semi circle are displayed as negative values 0 to 179 9 Permissible slewing speed The current speed reduction is displayed in the Start menu à p 9 19 The maximum permissible slewing speed is limited ...

Page 709: ...ovement will be stopped At the same time the slewing gear brake will be applied and lamp 1 will light up Slewing gear freewheel The slewing gear freewheel is required if the slewing gear needs to be slewed by means of external forces for example when operating with two cranes With the Brake pedal function switched on Switch on the slewing gear The slewing gear brake is released lamp 1 lights up Sh...

Page 710: ...amp in the button 1 will light up dimly Symbol 2 will be red if the slewing gear is switched off The slewing gear brake is applied lamp 3 lights up S Risk of damage to the main boom Brake the slewing movement down to a standstill before you switch off the slewing gear The slewing gear brake is automatically applied when the slewing gear is switched off This prevents excessive lateral forces affect...

Page 711: ...g message display 3 blue The slewing speed is not reduced automati cally If the maximum permissible slewing speed is exceeded the buzzer tone sounds once and the warning message 3 is displayed red H The entered limitations for the power unit speed of the slewing gear are still valid and the continuous speed reductions due to the working range limiter are still active s G Risk of accidents due to e...

Page 712: ...ping mechanism derricking gear and slewing gear can be operated in almost any combination simultaneously Restrictions are specified for the respective power units The auxiliary power units Superstructure lock tilt crane cab counter weight lifting unit cannot be operated with the Telescoping out movement Moving the auxiliary power units in combination with other power units can result in reductions...

Page 713: ...line the crane cab to the rear in order to attain a better sitting position when working at great heights A Incline to the rear Close the crane cab door Press the button 1 in at the top B Incline to the front Close the crane cab door The crane cab will tilt as long as you hold the button down or until its end position is reached G Risk of accidents due to objects overturning in the crane cab Close...

Page 714: ...stroke interval H The higher the selected value is the longer the pauses between the strokes of the wiper are Open the Datalogger 1 menu The displays 1 and 2 show the current values Select and confirm the symbol Select and confirm the symbol 7 Symbol is orange input on To cancel the input press button 9 once Change the value using buttons 8 or 10 Confirm the changed value 3 Interval for windscreen...

Page 715: ...ly if they are lower than the automatically limited values The automat ically limited values are not displayed The symbol 5 is only active when the auxil iary hoist is connected With the preselection symbol for Symbol 9 resets all values without prior selection Changing values Select and confirm the symbol for the relevant power unit symbol red Change the value using switch 2 or the buttons 3 To c...

Page 716: ...lso equipped with APS Auxiliary Power Supply there is a further third step in which the engine is shut down and an external generator started You can adjust the time interval between the steps Open the Economy menu 1 Switching on Select and confirm the symbol 2 Symbol 1 is displayed Adjusting the time interval Select and confirm the symbol 1 or 2 Change the value of the time intervals using switch...

Page 717: ...ted Activate step 3 manually Press and hold the button 1 for 3 seconds The engine for crane operation is switched off APS is started Economy Mode display If the Economy Mode is active a background image will be shown on the CCS display s Step 1 The engine speed is reduced Step 2 The superstructure drive is shut down Step 3 The engine is switched off APS1 is started automatically 1 Additional equip...

Page 718: ... accelerator pedal move a control lever switch on a power unit Switching off Select and confirm the symbol 2 Symbol 1 is displayed 11 6 6 Switching units of measure You can display the crane control values in metric units or US units Open the Switch units menu 1 Select and confirm the symbol The symbol 3 shows the respective confirmed selection 1 To display metric units 2 To display US units ...

Page 719: ...es to the power units Open the Settings 1 menu The symbols 2 show the set characteristic curves of the power units 1 Select the power unit for which you would like to change the characteristic curve Set the desired characteristic curve Select and confirm symbol 3 to reset all power units to characteristic curve 1 There are five characteristic curves The higher the number of the characteristic curv...

Page 720: ...itching on Push the switch 1 in at the bottom the lamp 2 lights up Switching off Push the switch 1 in at the top the lamp 2 goes out S Risk of damage to the slewable spotlights Make allowances for the position of the slewable spotlights before setting down the main boom This is prevent a collision between the working spotlights and the engine cover G Risk of accidents due to dazzling during on roa...

Page 721: ...sition The automatic load tracking can be switched on via the Spotlights menu Open the Spotlight 1 menu Automatic load tracking The pivoting spotlights must be manually aligned onto the load You can then switch on the automatic load tracking The spotlights automatically follow the load You can adjusting the pivoting speed of the spotlights Switch on the automatic load tracking symbol 2 You can adj...

Page 722: ...the torque reduction function for a limited time while working with the crane Select and confirm the symbol 1 symbol 3 appears The torque reduction function is overridden for 30 minutes After 30 minutes the torque is automatically reduced again You can override this reduction three times The torque is reduced continuously with each override starting at 80 down to 20 After the third override the sy...

Page 723: ... value 1 indicates the total operating hours for example 1 680 hours The value 2 shows the operating hours which can be reset Exception The value below the symbol 3 indicates how often the cycleUnlock telescopic section has been performed for example 13 750 times The value 4 shows the cycles this can be reset Reset The displayed operating hours cycles 3 can be reset Select and confirm the symbols ...

Page 724: ...Crane operation 11 6 Settings and displays for crane operation 11 134 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 725: ...ent before contact with the obstacle becomes imminent Do not deliberately move into the shutdown range You the crane opera tor are still responsible for monitoring the working range so that you can react appropriately if situations arise which cannot be monitored electron ically G Risk of accidents due to limits set too low When entering the limits bear in mind that even after switching off the en...

Page 726: ...splays The corresponding symbol is shown when a monitoring system is switched on The display shows 5 if the power unit speed has been reduced There are three displays 1 Hoist rope travel limitation monitoring 2 Overall height monitoring 3 Slewing angle monitoring 4 Working radius monitoring 1 Red Movement disabled 2 Yellow Speed reduced1 3 Green Speed not reduced 1 The maximum enabled power unit s...

Page 727: ...7 2 Opening the working range limiter menu If necessary open the overview of the menu groups and select the corresponding symbol 1 to 4 The corresponding menu will open and you can enter limit values and switch the monitoring on and off s 1 Permissible working range according to the Lifting capacity table shown darkened 2 Limited working range shown lightened 1 For the overall height à p 11 138 2 ...

Page 728: ...itoring is switched off Displays Accepting limit value Move the main boom head to just before the shutdown point without a load for example up to 17 5 m display 2 Select and confirm the display 2 The current value 2 will be accepted as the limit value 1 G Danger of accident due to incorrectly set limit values When entering the limit values please note that movements can still take place even after...

Page 729: ... confirm the input Display 1 shows the newly inputted limit value The distance X shows the current distance to the shutdown range Switch on monitoring Select and confirm the symbol 1 The Overall height monitoring is switched on H The movement towards the shutdown limit is continually reduced until reaching a standstill The current limitation is displayed à On the RCL dislay p 11 136 à On the CCSdi...

Page 730: ...itoring is switched off Displays Accepting limit value Move the main boom head to just before the shutdown point without a load for example up to 10 0 m display 2 Select and confirm the display 2 The current value 2 will be accepted as the limit value 1 G Danger of accident due to incorrectly set limit values When entering the limit values please note that movements can still take place even after...

Page 731: ... confirm the input Display 1 shows the newly inputted limit value The distance X shows the current distance to the shutdown range Switch on monitoring Select and confirm the symbol 1 The Working radius monitoring is switched on H The movement towards the shutdown limit is continually reduced until reaching a standstill The current limitation is displayed à On the RCL dislay p 11 136 à On the CCSdi...

Page 732: ...itched off Displays Permissible slewing range The slewing angle A limits slewing to the left The slewing angle B limits slewing to the right The permissible slewing range 6 green is the angle from A clockwise to B G Danger of accident due to incorrectly set limit values When entering the limit values please note that movements can still take place even after switching off which lead further into t...

Page 733: ...t from the left for example value 3 Select and confirm the display 3 The value 3 will be accepted as the limit value 4 for example 24 3 Entering limit values manually Slewing angle A I Select and confirm the display 1 II Enter the limit value for example 17 6 and confirm the input Display 1 shows the newly inputted limit value Slewing angle B II Select and confirm the display 2 III Enter the limit...

Page 734: ...2 01 2018 Switch on monitoring Select and confirm the symbol 1 The Slewing range monitoring is switched on H The movement towards the shutdown limit is continually reduced until reaching a standstill The current limitation is displayed à On the RCL dislay p 11 136 à On the CCSdisplay p 11 53 ...

Page 735: ...the current lift Entering limit values The values for the hoist rope limitation may not be entered until the tele scope 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 rope limitation then the RCL display will show an error message à Error messages on the CCS display p 14 8 s G Danger of accident ...

Page 736: ...5 is set as limit value 4 for Lower The symbol 3 confirms the entry Switch on monitoring Select and confirm the symbol 1 The Hoist rope travel monitoring is switched on H The movement towards the shutdown limit is continually reduced until reaching a standstill The current limitation is displayed à On the RCL dislay p 11 136 à On the CCSdisplay p 11 53 G Risk of accidents due to the hoist rope tra...

Page 737: ...ll be overridden and all movements enabled RCL display Shutdown point reached for Disabled movements Overall height Raising Extension Lowering the hoist Derricking the lattice extension Working radius Lowering the boom Extension Lifting the hoist Derricking the lattice extension Slewing angle A Slewing to the left Slewing angle B Slewing to the right Rope travel limitation Lifting Lifting Rope tra...

Page 738: ...Crane operation 11 7 Working range limiter 11 148 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 739: ...tched off Lamp 3 must light up slewing gear brake applied Switch the engine off turn the ignition key to position 0 and remove it Ensure that no unauthorised persons can operate the truck crane à To secure the truck crane p 11 150 G Risk of accident by suspended loads Never switch off the engine whilst a load is suspended You must have the control levers at hand in order to intervene at any time A...

Page 740: ...h the engine off turn the ignition key to position 0 and remove it Switch off all current consumers Switch off the battery master switch This will not interrupt the run down period of the heater To secure the truck crane Secure the truck crane against unauthorised use by Stowing away the hand held control in the crane cab Removing the ignition key Locking the crane cab G Danger due to unauthorised...

Page 741: ...rt the engine The heating output is only provided when the engine is running Open the Heating 1 menu Heating You must set the fan fresh air recirculated air and the temperature Setting the temperature Select and confirm the symbol 1 symbol is red Setting the fan Select and confirm the symbol 2 symbol is red Fresh air recirculated air mixed air Select and confirm the symbol 3 symbol is red Change a...

Page 742: ...ponding symbol 1 for the desired air vents Adjusting the air vents Switching off Switching off the heating system Reduce the temperature symbol 1 Switching off the ventilation Switch off the ventilation symbol 2 A Top only B Top and bottom C Bottom only 1 To open Press in and position lengthwise To close Position crosswise To direct the air flow In intermediate position 2 To direct the air flow Sl...

Page 743: ...to fresh air mode to ensure a fresh supply of oxygen at the same time Adjust the cooling output to your actual needs If the truck crane has been exposed to strong sunlight for a long period of time for example the air conditioning system should initially be operated at the highest blower level with the engine running The door or at least the windows should be left open for a short while to thoroug...

Page 744: ...t the desired air distribution symbol 3 Open the air vents if necessary Set the desired fan setting Symbol 4 Change and confirm the respective values using the controls 5 or 6 Cooling maximum You can also manually cool the crane cab without regulation The air condi tioning operates at maximum power and at the highest fan level Select and confirm the symbol 1 symbol is red Set the desired air distr...

Page 745: ... Find out whether there are any possible sources of danger that could result in an explosion The engine in the carrier is switched off and the ignition in the driver s cab is switched off à Switch off the engine p 4 18 Switch on the ignition in the crane cab à Switching the ignition on p 10 5 Select and confirm the symbol 1 the submenu opens s G Risk of explosion when operating the heating system ...

Page 746: ... confirm the respective values using the controls 3 or 4 Setting the heating start heating duration Select a weekday symbol 1 Set the starting time for the heating symbol 3 You can set up to three starting times Set the desired heating duration symbol 4 You can set a maximum heating duration of 2 hours Set the desired temperature symbol 2 Change and confirm the respective values using the controls...

Page 747: ... on Select a storage location for example 1 symbol 1 red You can also selected other storage locations The auxiliary heating now starts at the times stored in the corresponding column Switching off Select a storage location e g 1 symbol 1 grey You can also selected other storage locations Change and confirm the respective values using the controls 2 or 3 ...

Page 748: ...s The CraneSTAR system will be activated only at the request of the crane operator Information on viewing the transmitted data in the Internet can be found in the separate CraneSTAR Operating instructions and at www cranestar net here you will find all the information about activating the CraneSTAR system 11 10 2 Position of the components The CraneSTAR system includes an antenna and a TCU control...

Page 749: ...ng instructions which are indicated by cross references Observe the warnings and safety instructions there 12 1 1 CHECKLIST Rigging 1 Choose a suitable site à Choice of a suitable positioning site p 12 11 2 Check that the parking brake is engaged if necessary engage the parking brake 3 If the main boom is resting on a dolly Switch off the boom floating position à p 12 19 Switch off the slewing gea...

Page 750: ... and axle loads p 1 9 à Determining the required load bearing area p 12 11 5 Align the truck crane horizontally with the level adjustment system à Operating the level adjustment system p 5 53 6 On the outriggers Extend all outrigger beams as far as possible à p 12 49 Move all outrigger pads into the working position à p 12 53 Extend all outrigger cylinders far enough so that the outrigger pads are...

Page 751: ...st at point 12 8 Check whether the ground will support the maximum occurring outrig ger pressures à Determining the required load bearing area p 12 11 9 Deactivate Lock the suspension symbol red suspension off à p 5 17 10 Support the truck crane with the outrigger span required for the job according to the Lifting capacity table and raise until none of the wheels is touching the ground à Outrigger...

Page 752: ...ane p 12 15 14 Inspect the truck crane while looking out in particular for any leaking fluids oil fuel or water 15 Extend the step if necessary à p 12 157 16 Fold out the railing on the turntable à p 12 149 17 Start the engine for crane operation à p 10 3 18 Unlock the turntable and if necessary switch off the houselock à Unlocking the superstructure p 11 16 à Switching off the houselock p 11 19 ...

Page 753: ... à Reeving and unreeving the hoist rope p 12 124 20 Install lifting limit switch à p 12 139 21 Install the anemometer and if necessary the air traffic control light à Anemometer and air traffic control light p 12 145 22 Install the camera on main boom if required à Cameras for crane operation p 12 152 23 Fold out and adjust all mirrors for crane operation à p 12 150 24 Perform all the required che...

Page 754: ...rrent rigging mode à Enter rigging mode p 11 32 26 With the rigging mode adjusted accordingly rig the counterweight combination required for the operation according to Lifting capacity table à CHECKLIST Rigging the counterweight p 12 77 27 Enter the current rigging mode with the new rigged counterweight combination at the RCL display à Enter rigging mode p 11 32 ...

Page 755: ... unrig the counterweight à CHECKLIST Unrigging the counterweight p 12 79 2 Enter the current rigging mode with the new rigged counterweight combination at the RCL display à Enter rigging mode p 11 32 3 Depending on transport Attach the hook block to the bumper à p 12 116 or Set down the hook block and unreeve the hoist rope à Setting down the hook block p 12 118 à Unreeving hoist rope p 12 131 4 R...

Page 756: ... 3rd axle line à p 6 15 switch off the houselock à p 11 17 unrig the counterweight on the Rear counterweight platform à p 12 76 7 Turn off the engine for crane operation à p 10 11 8 If necessary remove the anemometer and air traffic control light à Anemometer and air traffic control light p 12 145 9 If necessary remove the camera from the main boom à Cameras for crane operation p 12 152 10 Fold in...

Page 757: ...0L 12 01 2018 11 Retract the step à p 12 157 12 Retracting the outriggers à CHECKLIST Retracting the outriggers p 12 43 13 Switch on suspension release locking symbol green suspension on à p 5 17 14 Switch off the engine 15 When the truck crane is no longer being used à In case of work breaks of more than 8 hours p 11 150 ...

Page 758: ...Rigging work 12 1 Rigging work checklists for crane operation with the main boom 12 10 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 759: ...site such that the unevenness of the ground can be compen sated for by adjusting the outrigger cylinders Maximum hoist of the outrigger cylinders à p 1 19 Choose a location where it is possible to keep the working radius to a min imum and where no obstacles are within the slewing range of the crane 12 2 1 Determining the required load bearing area The stability of the truck crane depends in the fi...

Page 760: ...CAPACITY OF THE GROUND Load bearing capacity t m2 lbs ft2 Backfilled not artificially compacted ground 0 to 10 0 to 2 050 Natural apparently undisturbed ground Mud peat marsh 0 Non cohesive ground which is sufficiently firm Fine to medium sand 15 3 070 Coarse sand to gravel 20 4 100 Cohesive ground Mushy 0 Soft 4 820 Stiff 10 2 050 Semi solid 20 4 100 Hard 40 8 200 Rock with minimal fissures in so...

Page 761: ...for calculating the required load bearing area If the outrigger pressure is 25 t and the ground has a load bearing capacity of 40 t m2 Then the required ground bearing area for this supporting cylinder is 0 625 m2 6 250 cm2 If the outrigger pad has a surface of 2 000 cm2 you would need to enlarge the ground bearing area by packing the outrigger pads à p 12 55 G Danger of overturning if the load be...

Page 762: ...ot supported As a rule of thumb If you are working on non cohesive or filled in ground the safety distance a must be twice as large as the pit depth b a 2 x b If you are working on cohesive undisturbed ground the safe distance a must be as great as the depth of the pit b a 1 x b The safe distance is measured from the base of the pit 3 In addition to this the safe distance d between the outrigger p...

Page 763: ... conductivity dampen the soil around the metal rod 3 Clamp an insulated cable 3 to the metal rod 2 cross section of at least 16 mm2 0 025 in2 Connect the free end of the cable using a clamp 1 Attach the clamp to the main boom or the superstructure B Risk of accident due to electric shock Earth the truck crane before you start to work with it Near strong transmitters radio transmitters radio statio...

Page 764: ...head power lines within the working range of the truck crane have these overhead power lines de energised if possible If this is not possible you must at least observe the prescribed safe distance A Different safe distances are recommended by the respective national regulations B Risk of accident due to electric shock The truck crane is not insulated If the truck crane its equipment its load lifti...

Page 765: ...act with you check that you are observing the safe distance A If the load has to be guided use only guide ropes of non conductive material If you do touch the overhead power cable Keep calm Do not leave the crane cab Tell anyone standing outside not to touch the truck crane the load or the lifting tackle Move the main boom out of the hazard area Voltage Safe distance A Up to 1 000 V 1 m 3 3 ft ove...

Page 766: ...Rigging work 12 2 Choice of a suitable positioning site 12 18 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 767: ...m pre tensioning if necessary à p 12 21 12 3 1 Switching off the boom floating position You must switch off the boom floating position before you raise the main boom off the dolly Remove the padlock 2 Switch over valve I lever 1 horizontal and pointing outward Secure the lever 1 with the padlock 2 Switch the valve IV over lever 3 points forwards The boom floating position is now switched off G Ris...

Page 768: ...e 1 Pull the pin 3 out as far as possible Secure the pin with the padlock in the bore 2 and remove the key Pull and secure the pin 3 on the other slewing gear in the same way Close the valve 5 the slewing gear freewheel is switched off Before slewing Support the truck crane with the necessary outrigger span enter the corre sponding rigging mode and derrick the main boom to an angle permissible wit...

Page 769: ... accumulator Switch off the boom floating position à p 12 19 The valves II and III are under the pressure gauge 1 Open valve II the lever 2 is vertical The pressure accumulator is emptied The pressure on the pressure gauge 1 must drop to 0 bar 0 psi The valve III stays closed lever 3 is horizontal S Danger of the hydraulic oil overheating Always switch the valve IV à p 12 19 over lever in horizont...

Page 770: ...Rigging work 12 3 Rigging work after driving with a dolly 12 22 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 771: ...control Operating manual 3 302 709 en 12 23 GMK5150L 12 01 2018 12 4 Connecting disconnecting the hand held control For operation Remove the hand held control 1 from the clamp 2 For transport Hang the hand held control 1 in the clamp 2 Close the covering 3 s ...

Page 772: ...en it is connected to the sockets 1 or 2 H Switch off the engine Pulling a bridging plug will shut the engine off but this action is only designed for emergencies The ignition can be switched on or off Socket Enabled operations 1 Emergency operation for crane movements except for telescoping mechanism Derrick lattice extension1 2 Emergency mode for crane operations 1 Additional equipment ...

Page 773: ...If the lamp 4 does not light up or if it flashes there is a malfunction à p 14 23 Disconnecting the hand held control Open the cap 2 Remove the plug 5 from the socket 1 the lamps 4 will go out Insert the bridging plug 3 into the socket 1 and secure it with the cap 2 The ignition is switched off unless it is switched on at an ignition lock G Danger due to unauthorised use Always stow the hand held ...

Page 774: ...Rigging work 12 4 Connecting disconnecting the hand held control 12 26 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 775: ...ing shutoff the engine with the hand held control Prerequisites The following requirements must be met before you can start the engine for driving with the hand held control The ignition is switched off in the crane cab The ignition is switched off in the driver s cab Connect the hand held control to a socket à p 12 25 s G Risk of crushing due to turning wheels When you start the engine no persons...

Page 776: ...on à p 14 23 Press the 3 button once the engine starts The following buttons are now active on the hand held control All buttons on the control panel 1 The function buttons 3 All buttons on the control panel 4 The button 6 for the horn on the carrier The button 2 and button 5 are inactive The Outriggers control units are locked after connection of the hand held control Turning off the engine If th...

Page 777: ...n start the engine for driving from the outrigger control units The ignition in the driver s cab must be switched on The ignition in the crane cab must be switched off The lamp 1 lights up Starting the engine All activities and inspections required to start the engine must be carried out before starting the engine à p 4 1 Press the button 1 once the engine will start Switch off the engine Press th...

Page 778: ...Rigging work 12 5 Starting the engine for rigging 12 30 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 779: ...outrigger spans are symmetrical All outrigger beams are extended and all outrigger beams are extended to the same outrigger span à Enabled outrigger spans p 12 32 12 6 1 Representation in the lifting capacity tables The outrigger span is always specified in this form in the Lifting capacity table Outrigger length xxxx outrigger width yyyyy Outrigger length The outrigger length I has a fixed value ...

Page 780: ...able for the Free on wheels working position The cover pages of the individual lifting capacity tables provide a brief overview in per cent G Risk of overturning when slewing the superstructure With some outrigger spans slewing is only permissible with certain counterweight combinations and boom positions à Slewing with rigged counterweight p 12 113 1 7 600 m 24 9 ft 2 6 700 m 22 0 ft 3 5 900 m 19...

Page 781: ...al different types of outrigger spans each with several permissible combinations Separate lifting capacity tables for the variable outrigger spans are provided in digital form Observe all the specifications and definitions in these tables before commencing operation 12 7 1 Definitions Specific terms and graphical illustrations are used in the description Directional information The directional inf...

Page 782: ... the outrigger widths 3 The outrigger width is specified as an indi vidual width II or overall width III depending on the type of the outrigger span Individual widths Overall widths The tables show the values for the outrigger widths 1 to 5 The individual widths and overall widths are specified in metres feet in the lifting capacity tables The cover pages of the lifting capacity tables provide a b...

Page 783: ... ger beams The overall width is entered once For example Right Left The outrigger span is the same at the left side and the same at the right side but different between the right and left sides The individual widths for the front and for the rear are entered For example Front rear The outrigger width is the same at the front and the same at the rear but different between the front and rear The ove...

Page 784: ... 3 Enabled outrigger spans Particular combinations are enabled for each type of outrigger span This section shows all released combinations with the associated individual widths of the outrigger beams Symmetrical The outrigger width is the same for all outrig ger beams The table shows the released combinations Front outrigger span 7 600 m 24 9 ft Rear outrigger span 3 800 1 250 m 12 5 4 1 ft FL FR...

Page 785: ...s type The lifting capacities for the Right greater than left type are enabled in a corre spondingly mirrored slewing range à Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables p 11 28 s FR RR FL RL I 3 800 m 12 5 ft 3 350 m 11 0 ft II 3 800 m 12 5 ft 2 950 m 9 7 ft III 3 800 m 12 5 ft 2 550 m 8 4 ft IV 3 350 m 11 0 ft 2 950 m 9 7 ft V 3 350 m 11 0 f...

Page 786: ...han front The rear outrigger beams are extended further than the front outrigger beams The table shows the permissible combinations FR FL RR RL I 3 800 m 12 5 ft 3 350 m 11 0 ft II 3 800 m 12 5 ft 2 950 m 9 7 ft III 3 800 m 12 5 ft 2 550 m 8 4 ft IV 3 350 m 11 0 ft 2 950 m 9 7 ft V 3 350 m 11 0 ft 2 550 m 8 4 ft FR FL RR RL I 3 350 m 11 0 ft 3 800 m 12 5 ft II 2 950 m 9 7 ft 3 800 m 12 5 ft III 2 ...

Page 787: ...ide is retracted The table shows the released combinations There are no separate lifting capacity tables for this type The lifting capacities for the One outrigger beam retracted left type are enabled in a correspondingly mirrored slewing range à Lifting capacities and slewing ranges for outrig ger spans without separate lifting capacity tables p 11 28 VR VL HR HL I 3 800 m 12 5 ft 1 250 m 4 1 ft ...

Page 788: ...Rigging work 12 7 Outriggers Overview MAXbase slewing range type 12 40 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 789: ...e level adjustment system and lower it as far as possible à p 5 53 2 Deactivate Lock the suspension symbol red suspension off à p 5 17 3 Engage parking brake à p 5 46 4 Extend all outrigger beams to the required span For the Standard slewing range type à p 12 32 For the MAXbase slewing range type à p 12 36 à Setting the outrigger spans p 12 46 à Extending retracting outrigger beams p 12 49 s G Dan...

Page 790: ...e load bearing area p 12 55 7 Extend the supporting cylinders until none of the wheels are touching the ground à p 12 56 8 Level the truck crane horizontally with the outriggers The lamp 1 lights up in the measuring range 1 à p 12 60 9 Check that none of the wheels are touching the ground Raise the wheels if necessary à Operating the axle raising system p 12 66 10 Switch off the engine After opera...

Page 791: ...s Observe the warnings and safety instructions specified here 1 Retract the outrigger cylinders as far as possible à p 12 56 2 Move the outrigger pads into the driving position and secure them à Moving into driving position p 12 53 3 Fully retract and secure all supports à For on road driving p 12 49 à Extending retracting outrigger beams p 12 49 4 Stow away packing material safely if applicable 5...

Page 792: ...h the level adjustment system à Operating the level adjustment system p 5 53 Locking the suspension Switch off the suspension à Switching the suspension on off p 5 16 The control elements for the outriggers are only released if the suspension is switched off If the suspension is switched off the wheels are lifted when the crane is put on outriggers Crane cab The outriggers can be moved from the cr...

Page 793: ...he control units on Select and confirm the symbol 1 symbol 1 red symbol 2 grey The outriggers cannot now be operated via the CCS display Switch the control units off Select and confirm the symbol 2 symbol 2 red symbol 1 grey The outriggers can now be operated via the CCS display Outrigger lighting on off You can switch the outrigger lighting on and off from the crane cab Switching on Select symbol...

Page 794: ...12 5 ft A Prerequisite Pins 1 and 2 must be pulled out B Setting and securing Extend the outrigger beam up to the marking 3 Secure the outrigger beam with the pins 1 and 2 For the overall width Set the same outrigger span in the same way at the opposite outrigger beam G Danger of overturning if the outrigger beams are not correctly extended Extend the outrigger beams only as far as the permissible...

Page 795: ...rigger beam with the pins 1 and 2 For the overall width Set the same outrigger span in the same way at the opposite outrigger beam Outrigger span 66 Overall width 8 030 x 5 900 m 26 3 x 19 4 ft Individual width 8 030 x 2 950 m 26 3 x 9 7 ft A Prerequisites Pin 1 must be removed Pin 2 must be inserted B Setting and securing Extend the outrigger beam up to the marking 3 Secure the outrigger beam wit...

Page 796: ...ng 3 Secure the outrigger beam with the pin 1 The pin 2 remains inserted For the overall width Set the same outrigger span in the same way at the opposite outrigger beam Outrigger span 0 Overall width 8 030 x 2 500 m 26 3 x 8 2 ft Individual width 8 030 x 1 250 m 26 3 x 4 1 ft A Prerequisites Pins 1 and 2 must be pulled out B Setting and securing Completely retract the outrigger beam Secure the ou...

Page 797: ...hem observed by a banksman who is in visual contact with you G Danger of overturning if improperly supported Always extend all outrigger beams to the required outrigger span required for the specified rigging mode even if you are only working on one side Otherwise the rear stability for the rigging mode according to the displayed rigging mode is no longer guaranteed S Risk of damage to the outrigg...

Page 798: ...nits à p 12 50 In the crane cab à p 12 50 From the crane cab The following operating elements are found in the Outriggermenu The parking brake is engaged Starting the engine Start the engine from the crane cab à p 10 3 Switch off the slewing gear à p 11 120 Menu open Open the Outrigger menu 1 Select and confirm the symbol 2 Move outrigger beams Extending Press the button for the desired outrigger ...

Page 799: ...at the bottom the selected outrigger beam retracts From the control units Starting the engine Start the engine from the driver s cab à p 4 13 You can also start the engine from the control units à p 12 27 Switching on the lighting Only the lamp 1 lights up after opening the door Press any button The lights are switched on s 1 Front left 2 Front right 3 Rear left 4 Rear right ...

Page 800: ...erator s side Observe the safety instructions for operating the outriggers à p 12 49 Press the button Additionally press the button for the desired outrigger beam The outrigger beams move until you let go of the respective button or until the respective end position has been reached 5 For high speed mode 6 For normal speed 1 Extend left 2 Retract left 3 Retract right 4 Extend right 1 4 Extend both...

Page 801: ...ndle 2 Secure the outrigger pad with the pin 1 Secure the pin 1 Move the other outrigger pads into operat ing position in the same way Securing pin Plug the pin with the peg 1 through the cutout 2 Turn the grip 3 downwards Moving into driving position A Pull out the pin 1 B Pull the outrigger pad by the handle 2 onto the holder 3 Secure the outrigger pad with the pin 1 Secure the pin 1 Move the ot...

Page 802: ...Rigging work 12 8 Outrigger operation 12 54 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 803: ... the packing has several layers each layer must be placed below the other offset by 90 The packing must lie flat on the ground Consult your supervisor if you are in doubt H If the truck crane is equipped with plastic outrigger pads then the uppermost layer of the packing must be a steel plate 1 of sufficient strength G Risk of accidents if the packing is insufficient Only use materials of sufficie...

Page 804: ...d the resulting outrigger pressure This prevents the ground under the outrigger pad giving way and causing the truck crane to tilt and overturn G Risk of accidents if the supporting cylinders are out of sight No one is allowed to be in the area of the supporting cylinders Observe the moving supporting cylinders or have them observed by a banksman who is in visual contact with you S Risk of damage ...

Page 805: ... 12 56 The operation is the same for all supporting cylinders Press the button Also press the button for the desired supporting cylinder e g for 4 1 You can also operate several supporting cylinders at the same time The supporting cylinders move until you let go of the respective button or until the respective end position has been reached s 1 Supporting cylinder 1 1 2 Supporting cylinder 2 1 3 Su...

Page 806: ...enu Starting the engine Start the engine from the crane cab à p 10 3 Switch off the slewing gear Menu open Open the Outrigger menu 1 Select and confirm the symbol 2 Move outrigger cylinders Extend Press the button for the desired outrigger cylinder Press the button 5 in at the top the selected supporting cylinder extends 1 Front left 2 Front right 3 Rear left 4 Rear right ...

Page 807: ...ating manual 3 302 709 en 12 59 GMK5150L 12 01 2018 Retracting Press the button for the desired outrigger cylinder Press the button 5 in at the bottom the selected supporting cylinder retracts 1 Front left 2 Front right 3 Rear left 4 Rear right ...

Page 808: ...suring ranges You can change the measuring range between 1 and 5 Press the button 2 once The current measuring range 1 is displayed The measuring range is automatically switched in the Outrigger menu and the Monitoring menu Read the display Only the lamp 1 at the centre is on if the truck crane is level The other lamps show the sides of the truck crane which are higher RCL CCS display The assignme...

Page 809: ...isites apply to manual and automatic alignment The main boom must be resting in the boom rest Or The main boom must be raised and the load must have been set down and the superstructure must be in the 0 or 180 position s G Risk of overloading the main boom Always slew the superstructure to the 0 or 180 position and set down the load before levelling the truck crane In other positions the deformati...

Page 810: ... ground that the ground has not given way under any of the outrigger pads that the packing is correct for the enlarged load bearing area If slewing is permissible in the current rigging mode Slew the superstructure within the permissible slewing range Perform the specified checks again Check the horizontal alignment on the inclination indicator Automatic alignment During the automatic alignment pr...

Page 811: ...r pads touch the ground 2 All the supporting cylinders are extended simultaneously so that none of the wheels is touching the ground any more 3 The truck crane is automatically leveled horizontally This procedure is performed until horizontal alignment is reached the lamp 1 in the centre is the only one lighting up in measuring range 1 or until you let go of a button or until horizontal alignment ...

Page 812: ...until all wheels are just above the ground Levelling the truck crane Level the truck crane with the outriggers until only lamp 1 is illuminated in the measuring range 1 G Danger of overturning if the supporting cylinders are operated unevenly Extend or retract the supporting cylinders as evenly as possible This prevents the truck crane overturning while retracting individual outrigger cylinders G ...

Page 813: ...is switched on Now all wheels are lowered to the ground and are in the right position for the horizontal alignment Switching off the suspension Select and confirm the symbol 1 once The symbol 2 is red if the suspension is switched off To secure the truck crane Retract the supporting cylinders until the outrigger pads are about 5 to 10 cm 2 to 4 in above the ground Leave the outrigger beams extende...

Page 814: ...locked suspension without first supporting the truck crane on outriggers Menu open The Raise axle menu can only be opened when the suspension is switched off locked à Switching the suspension on off p 5 16 Press button 2 repeatedly until the Raise Axle menu 1 is displayed The assignment to the carrier corresponds to the top view The operation is same on both sides Only certain wheel groups can be ...

Page 815: ...on Operating manual 3 302 709 en 12 67 GMK5150L 12 01 2018 Press the button for the desired movement Lifting lowering wheels Aligning the truck crane 1 Lifting wheels 2 Lowering wheels 1 Lowering the truck crane 2 Lifting the truck crane ...

Page 816: ... the outrigger pressure table always determines the load on the ground The set unit t or klbs is shown next to the displays H Outrigger cylinders retracted or extended as far as possible will lead to an incorrect outrigger pressure display The display will show the most accurate reading if the movement per formed last was Extend outrigger cylinders In the Outrigger menu The assignment of the displ...

Page 817: ... 12 01 2018 On the outrigger control units The assignment of the displays to the carrier corresponds to the top view 1 Display for the supporting cylinder 1 1 2 Display for the supporting cylinder 2 1 3 Display for the supporting cylinder 3 1 4 Display for the supporting cylinder 4 1 ...

Page 818: ...Rigging work 12 8 Outrigger operation 12 70 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 819: ... engine is running for crane operation the rigging personnel may only climb on the truck crane when the slewing gear is switched off and the slewing gear brake is applied The crane operator and rigging personnel must maintain visual contact during the rigging process The rigging process for a single counterweight section is described Proceed in the same manner when rigging other counterweight sect...

Page 820: ...range of the counterweight and the load As the crane operator Perform the Raise hoist movement at the lowest possible speed until the lifting gear is free When unrigging As the crane operator Lift the lifting gear over the counterweight section Now inform the rigging personnel that they can climb on the truck crane As the rigging personnel Do not climb on the truck crane until permitted by the cra...

Page 821: ...axle loads of 12 t Counterweight one 2 3 t base plate 1 one 2 3 t section 2 two 4 6 t blocks 3 one 4 6 t block 4 one 2 3 t section 5 one 4 6 t section 6 one 2 3 t section 7 one 2 3 t section 8 one 1 0 t plate 9 or the auxiliary hoist 10 two 6 8 t blocks 11 Version 2 With this version 24 t maximum counterweight can be transported with the truck crane The axle loads are over 12 t Counterweight one 1...

Page 822: ...on 3 This version enables you to drive with maximum axle loads of 12 t Counterweight one 1 0 t plate 1 or the auxiliary hoist 8 one 2 3 t base plate 1 two 2 3 t sections 2 three 4 6 t sections 3 one 4 6 t section 4 one 2 3 t section 5 one 2 3 t section 6 one 1 0 t plate 7 or the auxiliary hoist 8 two 6 8 t blocks 9 ...

Page 823: ...e and the counterweight sections are labelled with the serial number 1 Depending on the version other counter weight sections e g blocks are labelled with a serial number 1 S Danger if counterweight sections are interchanged Operate the truck crane only with the counterweight sections that belong to it The truck crane and counterweight sections are labelled with the same serial number Other or add...

Page 824: ...ts p 1 14 Sections Attach the counterweight sections at the slinging points 1 Blocks Sling the blocks at the slinging points 1 G Risk of accident if used improperly Attach the lifting gear to various counterweight section only at the appro priate slinging points Ensure the lifting gear has sufficient load bearing capacity Lift a maximum of two stacked 4 6 t plates The slinging points of the other ...

Page 825: ... For the Standard slewing range type à p 12 32 For the MAXbase slewing range type à p 12 36 2 Enter and confirm the current rigging mode à p 11 32 3 Assemble the required combination of counterweights à Slinging points on the counterweight sections p 12 76 à Assembling counterweight combination p 12 80 4 Slew the superstructure to the 0 to the rear position à Braking the slewing movement p 11 119 ...

Page 826: ... p 12 104 Slew the superstructure into the rigging range and lift counterweight to the turntable automatic and pre charge à p 12 106 6 Enter the current rigging mode with the new rigged counterweight combination at the RCL display à p 11 32 7 Only switch on the slewing gear if slewing is permissible for the current outrigger span à Slewing with rigged counterweight p 12 113 ...

Page 827: ...he superstructure to the 0 to the rear position à Braking the slewing movement p 11 119 3 Open Counterweight menu Correct the rigging mode if necessary à p 12 104 Use the automatic system to lower the counterweight on to the counterweight platform à p 12 106 4 Enter the current rigging mode with the currently rigged counterweight combination à p 11 32 5 Lift the counterweight sections off the coun...

Page 828: ... capacity table Other combinations are not permitted If other versions are assembled the truck crane is no longer protected against overloading by the RCL G Risk of crushing when setting down the counterweight sections Make sure the helpers keep a sufficient distance away from the counter weight sections with any parts of their body when setting down the coun terweight sections Remove all objects ...

Page 829: ...ase plate in such a way that the holders 1 grip into the recesses 2 For larger counterweight combinations now set additional counterweight sections onto the 2 3 t base plate Setting down the top couterweight section With versions 1 2 and 3 Always place a plate with cutouts 1 as the uppermost counterweight section Only then can the lifting cylinder be rotated into the 2 3 t base plate s S Risk of d...

Page 830: ... Operating manual GMK5150L 12 01 2018 Version 1 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 831: ...71 2 4 6 10 142 31 4 6 10 142 41 2 3 5 071 5 4 6 10 142 6 2 3 5 071 7 2 3 5 071 8 1 0 2 205 92 6 8 14 991 1 0 2 205 3 3 7 275 4 5 6 12 346 5 4 7 9 17 417 3 3 4 3 7 6 7 1 Must always lie on 2 2 Or use 0 3 Must always lie on top 4 Must be installed on the turntable 5 7 Must be installed under 8 6 7 Must lie on top or lie under 8 or installed under 8 7 8 Must lie on top or be installed on the turntab...

Page 832: ...09 en Operating manual GMK5150L 12 01 2018 The illustration and the table show all counterweight sections and all coun terweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 833: ... 142 41 2 3 5 071 5 4 6 10 142 6 2 3 5 071 7 2 3 5 071 8 1 0 2 205 92 6 8 14 991 10 2 22 487 3 3 4 6 7 3 5 4 12 5 27 558 3 3 4 3 5 4 14 8 32 628 2 x 3 4 3 5 4 17 1 37 699 2 x 2 x 3 2 x 7 3 5 4 1 Must always lie on 2 2 Or use 0 3 Must always lie on top 4 Must be installed on the turntable 5 7 Must be installed under 8 6 7 Must lie on top or lie under 8 or installed under 8 7 8 Must lie on top or be...

Page 834: ...09 en Operating manual GMK5150L 12 01 2018 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 835: ... 31 4 6 10 142 41 2 3 5 071 5 4 6 10 142 6 2 3 5 071 7 2 3 5 071 8 1 0 2 205 92 6 8 14 991 19 4 42 770 2 x 2 x 2 x 3 2 x 7 2 x 6 7 21 7 47 840 2 x 2 x 2 x 3 2 x 3 2 x 7 2 x 7 2 x 6 7 1 Must always lie on 2 2 Or use 0 3 Must always lie on top 4 Must be installed on the turntable 5 7 Must be installed under 8 6 7 Must lie on top or lie under 8 or installed under 8 7 8 Must lie on top or be installed...

Page 836: ...09 en Operating manual GMK5150L 12 01 2018 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 837: ... 5 071 7 2 3 5 071 8 1 0 2 205 92 6 8 14 991 24 0 52 911 2 x 2 x 3 2 x 3 2 x 7 2 x 7 2 x 6 7 2 x 6 7 26 3 57 982 2 x 2 x 3 2 x 7 2 x 6 7 2 x 6 7 30 9 68 123 2 x 8 6 7 44 5 98 106 2 x 8 6 7 2 x 1 Must always lie on 2 2 Or use 0 3 Must always lie on top 4 Must be installed on the turntable 5 7 Must be installed under 8 6 7 Must lie on top or lie under 8 or installed under 8 7 8 Must lie on top or be...

Page 838: ... Operating manual GMK5150L 12 01 2018 Version 2 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 839: ...nter weight combina tion in t lbs 2 3 5 071 1 2 3 5 071 2 4 6 10 142 2 x 31 2 3 5 071 4 4 6 10 142 5 9 2 20 283 62 1 0 2 205 73 6 8 14 991 9 1 0 2 205 3 3 7 275 5 6 12 346 7 9 17 417 4 10 2 22 487 4 12 5 27 558 4 14 8 32 628 17 1 37 699 4 19 4 42 770 4 1 Must always lie on 2 2 Must be installed on the turntable 3 Or use 8 4 Must always lie on top ...

Page 840: ...09 en Operating manual GMK5150L 12 01 2018 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 841: ...s in t lbs Counter weight combina tion in t lbs 2 3 5 071 1 2 3 5 071 2 4 6 10 142 2 x 31 2 3 5 071 4 4 6 10 142 5 9 2 20 283 62 1 0 2 205 73 6 8 14 991 9 19 4 42 770 4 21 7 47 840 4 24 0 52 911 26 3 57 982 30 9 68 123 4 44 5 98 106 4 2 x 1 Must always lie on 2 2 Must be installed on the turntable 3 Or use 8 4 Must always lie on top ...

Page 842: ... Operating manual GMK5150L 12 01 2018 Version 3 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 843: ... 142 4 2 3 5 071 5 2 3 5 071 6 1 0 2 205 71 6 8 14 991 9 1 0 2 205 3 3 7 275 3 5 6 12 346 1 x 5 5 4 7 9 17 417 2 x 1 x 2 1 x 5 1 x 7 6 7 10 2 22 487 1 x 1 x 2 1 x 2 1 x 2 7 1 x 2 6 7 1 Or use 8 2 1 x 3 can be replaced with 4 3 Must be installed on the turntable 4 5 Must be installed under 6 5 Must always lie on top 6 5 Must lie on top or lie under 6 or installed under 6 7 6 Must lie on top or be i...

Page 844: ...09 en Operating manual GMK5150L 12 01 2018 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 845: ...2 3 5 071 5 2 3 5 071 6 1 0 2 205 71 6 8 14 991 9 12 5 27 558 2 x 1 x 2 2 x 2 1 x 2 5 1 x 2 7 2 x 6 7 1 x 2 6 7 14 8 32 628 1 x 2 x 2 2 x 1 x 2 5 1 x 1 x 2 5 2 x 1 x 2 7 1 x 1 x 2 7 2 x 6 7 1 Or use 8 2 1 x 3 can be replaced with 4 3 Must be installed on the turntable 4 5 Must be installed under 6 5 Must always lie on top 6 5 Must lie on top or lie under 6 or installed under 6 7 6 Must lie on top ...

Page 846: ...09 en Operating manual GMK5150L 12 01 2018 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 847: ... 14 991 9 17 1 37 699 2 x 2 x 2 2 x 2 1 x 3 x 2 5 1 x 3 x 2 7 2 x 1 x 2 6 7 2 x 2 6 7 19 4 42 770 1 x 3 x 2 2 x 2 5 3 x 2 5 2 x 2 7 3 x 2 7 1 x 2 x 2 21 7 47 840 2 x 3 x 2 3 x 2 1 x 3 x 2 5 1 x 3 x 2 7 2 x 2 x 2 6 7 3 x 2 6 7 1 Or use 8 2 1 x 3 can be replaced with 4 3 Must be installed on the turntable 4 5 Must be installed under 6 5 Must always lie on top 6 5 Must lie on top or lie under 6 or in...

Page 848: ...709 en Operating manual GMK5150L 12 01 2018 The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 76 ...

Page 849: ... 14 991 9 24 0 52 911 1 x 3 x 2 x 3 x 2 5 3 x 5 2 x 3 x 2 7 3 x 7 1 x 3 x 2 6 7 26 3 57 981 2 x 3 x 1 x 3 x 5 1 x 3 x 7 2 x 3 x 2 6 7 3 x 6 7 30 9 68 123 2 x 3 x 8 6 7 44 5 98 106 2 x 3 x 8 6 7 1 Or use 8 2 1 x 3 can be replaced with 4 3 Must be installed on the turntable 4 5 Must be installed under 6 5 Must always lie on top 6 5 Must lie on top or lie under 6 or installed under 6 7 6 Must lie on ...

Page 850: ...To lift and lower the counterweight the lifting cylinders are screwed into the 2 3 t base plate 2 Counterweight menu To operate the counterweight hoist unit you must open the Counterweight menu Open menu Open the Counterweight menu 1 G Risk of crushing when lifting and lowering the counterweight Make sure nobody is on the counterweight platform while the counter weight is being lifted or lowered ...

Page 851: ...rging the counterweight afterwards H Always lift and lower the counterweight in automatic mode otherwise slewing with extended lifting cylinders will be blocked à Automatic mode rigging p 12 105 à Automatic mode unrigging p 12 107 s 1 Slewing blocked pre clamp the counter weight à p 12 105 2 Contact Manitowoc Crane Care 3 If the pre tensioning pressure continues to drop the message 1 S Risk of dam...

Page 852: ...g mode as follows Slew the superstructure out of the rigging range so that the lifting cylinders can be freely extended Assuming the symbol 4 is yellow with the counterweight unrigged Press in the override button 3 upwards A Fully extend the lifting cylinders symbol 1 Release the override button 3 B Fully retract the lifting cylinders button 2 The symbols 4 become green You can now use the automat...

Page 853: ...tic mode rigging While the automatic mode is being executed you can always Cancel the automatic mode à Cancel automatic mode p 12 108 Interrupt the automatic mode by letting go of the control lever After moving the lever in the displayed direction once more the automatic mode is continued Prerequisites The counterweight combination must be assembled The lifting cylinders must be fully retracted sy...

Page 854: ...l lever in the dis played direction 1 or 2 the automatic mode starts The superstructure turns into position A The lifting cylinders are extended B Release the control lever Move the slewing control lever in the dis played direction 1 or 2 the automatic mode continues The superstructure turns into position C The lifting cylinders are retracted D The counterweight is pre charged symbol 3 green Relea...

Page 855: ...the displayed direction once more the automatic mode is continued Prerequisites The lifting cylinders must be fully retracted symbol 3 green The slewing gear is switched symbol 1 green The superstructure must be in the rigging range Symbol 4 active Symbol 2 displayed Switch on automatic mode Select and confirm the symbol 3 Execute automatic mode Move the slewing control lever in the dis played dir...

Page 856: ...matic mode You can cancel the automatic mode any time Press in the override button 1 upwards the automatic mode is cancelled If you have cancelled the automatic operation then you must In position A Fully retract the lifting cylinders symbol 1 In position B Turn the superstructure into position A Fully retract the lifting cylinders symbol 1 S Risk of damage to the counterweight With the override s...

Page 857: ...and 3 Use automatic mode to lift the counter weight combination onto the turntable à Automatic mode rigging p 12 105 Unscrew the bolts 1 and remove the clamp 2 from the bracket 3 Use automatic mode to lower the counter weight combination onto the turntable Version 2 Secure the mounted 9 2 t plate using suita ble lifting gear so that the plate cannot fall down during removal Unscrew the bolts 1 and...

Page 858: ... using the bolts 1 tightening torque 75 Nm 55 3 lbf ft If no further work is to be performed using the truck crane Use automatic mode to lower the counter weight combination onto the turntable Version 2 Use suitable auxiliary equipment e g fork lift to lift the 9 2 t plate onto the turntable until the connecting points line up Insert the bracket 3 through the counter weight section from below Push...

Page 859: ...nds on the driving mode of the truck crane à Driving modes p 6 1 With all versions the 1 t compensation weight or the auxiliary hoist is mounted on the turntable Versions 1 and 3 For driving with axle loads up to 12 t The 2 3 t plates 1 and 2 are mounted on the turntable The 2 3 t base plate 3 is on the counter weight platform or for the respective driving mode The 2 3 t plates 1 and 2 are mounted...

Page 860: ...ase plate 6 and the 2 3 t plate 5 lie on the counterweight platform the 4 6 t counterweight blocks 4 lie on the 2 3 t counterweight section 5 the 4 6 t counterweight section 3 is attached to the rear storage area Fasten the counterweight on the rear storage area Fasten the holder 1 to the carrier Place the 4 6 t counterweight block on the holder 1 Secure the pins 4 6 t counterweight block using th...

Page 861: ...ible working radius according to Lifting capacity table is maintained G Danger of overturning when slewing with an incorrectly set RCL The RCL only disables the slewing operation if you have entered the RCL code correctly and if the RCL is not overridden Before slewing always check that the current rigging mode is shown on the RCL display This prevents slewing operations from being enabled within ...

Page 862: ...Rigging work 12 9 Rigging unrigging the counterweight 12 114 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 863: ...t bumper à Driving modes p 6 1 The main boom must be fully retracted Enter and confirm the current rigging mode Slacken the hoist rope and raise the main boom simultaneously Raise the main boom until the boom head is in a vertical position above the hook block Detach the hook block from the retaining rope 1 s S Risk of accidents if the view is obstructed Have someone instruct you when raising the ...

Page 864: ...nd pull the hoist rope tight only to the extent that the hook block is stabilised in its position H If the lifting limit switch is deactivated while you tighten the hoist rope you can override the shutdown of the lifting limit switch à p 11 83 G Risk of accidents if the view is obstructed The reeved rope lines obstruct the view of the runway The number of legally permissible rope lines can vary de...

Page 865: ...dard slewing range type enter a rigging mode for the 360 working range or for the MAXbase slewing range type enter a working radius for which slewing is enabled This prevents slewing into impermissible areas and the truck crane tipping over as a result S Risk of damage to the separate vehicle Raise the hook block from the separate vehicle only when the main boom head is directly above the hook blo...

Page 866: ...the boom head is directly above the hook block 1 Unreel the hoist rope Reeve the hoist rope into the hook block 1 à Reeving and unreeving the hoist rope p 12 124 Raise the hook block off the separate vehicle Setting down the hook block Depending on the driving mode the hook block must be set down on a separate vehicle à Driving modes p 6 1 With the RCL set accordingly fully retract the main boom R...

Page 867: ... 1 for transport Set down the main boom on the boom rest Fastening the hoist rope to the bumper Do not attach the rope end clamp to the front towing coupling The towing coupling must be free for a tow rod in emergencies Attach the rope end clamp to the retaining rope 1 Pull the hoist rope slightly taut Fasten the lifting limit switch weight to the hoist rope The hoist rope and lifting limit switch...

Page 868: ...n a separate vehicle Rigging for on road driving A Remove the retaining pin and pull out the pins 3 B Raise the block hook 1 an Insert the pins 3 and secure them in the hook Stow away the hook 2 so that it is safe for trans portation Raise the block hook 1 vertically above the holding ropes 2 Lower the block hook 1 and fasten it using the holding ropes 2 Set down the main boom onto the boom rest a...

Page 869: ...hoist rope and raise the main boom simultaneously Raise the main boom until the boom head is in a vertical position above the block hook 1 Detach the block hook from the retaining ropes 2 A Pull the pin 3 out B Raise the hook block 1 above the hook 2 until the connecting points are aligned Insert the pins 3 and secure them with the retaining pins ...

Page 870: ...k block weight to the weight required according to the Lifting capacity table Weight version A à p 1 12 Weight version A à p 1 13 Removing Remove the securing plugs and pull out the pins 2 Remove the ballast plates 1 In this way remove the ballast plates alter nately from both sides If all ballast plates have not been removed make sure that the number of remaining bal last plates are equal on both...

Page 871: ...heck that the hook blocks have room to move freely especially for two hook operation G Risk of accident due to falling ballast plates Always secure the ballast plates with the pins and the securing plugs Always check the completeness and condition of the securing plugs before operating the crane This prevents ballast plates from falling down during crane operation S Risk of damage to the hook bloc...

Page 872: ... required load bearing capacity Four reeved rope lines correspond for example to 4 fall reeving à Possible reevings on the main boom p 12 132 To reeve and unreeve the hoisting rope you must remove the pocket lock After reeving you must reattach the pocket lock There are A or B versions Version A Removing Pull the pin 2 out and remove the fork element 1 Slide the holder 3 back and remove it from th...

Page 873: ... Positioning Plug the holder 3 and slide it onto the hoist rope as far as it will go 4 Fasten the fork 1 using the pin 2 Secure the pin Version B Removing Remove the linchpin 4 Release the locknuts 3 and pull out the pins 1 Remove the bracket 2 Slide the padlock 5 back and remove it from the hoist rope 6 s ...

Page 874: ... pin 1 as far as it will go and then turn by one half turn Insert the linchpin 4 Fastening the pocket lock on the main boom Fasten the pocket lock to the fixed point of the main boom in such away that the locknut 1 faces outward and The locknut 2 faces forward in the driving direction S Risk of damage to the hoist rope Always install the pocket lock as it is described in the following paragraph Th...

Page 875: ...ted into the position via which the hoist rope will run for example into position 2 Shifting the head sheave A Pull the rod 5 out Turn the lever 3 so that it is located below the cutouts 1 or 2 B Push the head sheave 4 into the required position e g into position 2 Turn the lever 3 into the appropriate cutout e g into cutout 2 Insert the rod 5 and secure it with the retaining pins s G Danger due t...

Page 876: ...12 122 Opening the hook block Pull out the rods 2 Fold down the plates 3 Positioning the hoist rope Pull out the rods 1 and 4 Feed the main hoist rope 2 under the rope grab 1 If two hoist ropes are reeved you must feed the auxiliary hoist rope 5 over the rope grab Feed the main hoist rope to the head sheave 3 Feed the auxiliary hoist rope to the head sheave 4 Use the rope grab also when working wi...

Page 877: ...Reeve the hoist rope with the required number of lines Possible reevings à p 12 132 Fastening the hoist rope The fixed point used depends on the number of reeved rope lines Depending on the version the centre fixed point 2 may be present on main booms with 5 head sheaves Fixed points for an even number of lines The rope end clamp is fastened to a fixed point 1 or 2 for 2 fall 4 fall 6 fall reev in...

Page 878: ...pin 2 A If there is an even number of lines to a fixed point 1 of the main boom head B If there is an uneven number of lines to a fixed point 1 of the hook block Secure the pin 2 with the safety hinged pin Securing the hoist rope Insert the rods 1 and 4 Secure all the rods Closing the hook block Fold up the plates 3 on both sides Insert the rods 2 and secure them ...

Page 879: ... Fold down the plates 1 Remove the rope end fitting from the fixed point 2 or 4 Unreeve the hoist rope Insert the rods 5 and 3 and secure them Depending on the driving mode you can Fasten the hoist rope to the bumper à p 12 119 or Pull out the rods 1 2 and roll the hoist rope 3 on to the drum Insert the rods 1 2 and secure them Secure the hoist rope 3 ...

Page 880: ...oom Possible reevings on lattice extensions and the auxiliary single sheave boom top à Lattice extension operating manual H The maximum lifting capacity is specified in the supplied lifting capacity table With 6 head sheaves If 8 head sheaves are provided à p 12 135 If 9 head sheaves are provided à p 12 138 6 sheave hook block Reeving A 12 fall ...

Page 881: ... Rigging work on the main boom Operating manual 3 302 709 en 12 133 GMK5150L 12 01 2018 5 sheave hook block 3 sheave hook block s Reeving A 11 fall B 10 fall C 9 fall D 8 fall Reeving A 7 fall B 6 fall C 5 fall D 4 fall ...

Page 882: ...Rigging work 12 10 Rigging work on the main boom 12 134 3 302 709 en Operating manual GMK5150L 12 01 2018 1 sheave hook block Hook tackle Reeving A 3 fall B 2 fall C 1 fall Reeving A 1 fall ...

Page 883: ... 3 302 709 en 12 135 GMK5150L 12 01 2018 With 8 head sheaves With additional equipment 8 head sheaves may be present If 6 head sheaves are provided à p 12 132 8 sheave hook block 7 sheave hook block s Reeving A 16 fall Reeving A 15 fall B 14 fall C 13 fall D 12 fall ...

Page 884: ...0 Rigging work on the main boom 12 136 3 302 709 en Operating manual GMK5150L 12 01 2018 5 sheave hook block 3 sheave hook block Reeving A 11 fall B 10 fall C 9 fall D 8 fall Reeving A 7 fall B 6 fall C 5 fall D 4 fall ...

Page 885: ...Rigging work 12 10 Rigging work on the main boom Operating manual 3 302 709 en 12 137 GMK5150L 12 01 2018 1 sheave hook block Hook tackle s Reeving A 3 fall B 2 fall C 1 fall Reeving A 1 fall ...

Page 886: ...ing manual GMK5150L 12 01 2018 With 9 head sheaves The 7th head sheave of the auxiliary single sheave boom top 1 is used for this version 9 pulley hook block1 Reeving A 18 falls2 1 Additional equipment à Lattice extension operating manual 2 Only with special equipment à p 1 7 ...

Page 887: ...head Install the switch on the side that is closer to the last rope line leading upwards There can also be one lifting limit switch installed on each side On the left side Fit the lifting limit switch 3 onto the clamp 2 and secure it with the retaining pin Lay the cable 4 so that it will not be dam aged during crane operation and insert the lifting limit switch into the socket 1 On the right side ...

Page 888: ...imit switch weight has been attached If the lifting limit switch weight has for example been attached to the left lifting limit switch 1 you must lock the right lifting limit switch 2 à Locking p 12 144 Otherwise the movements Raise hosting gear Telescope out and Lower the boom will be locked S Risk of damage if the lifting limit switch is locked The lifting limit switch must not be locked Remove ...

Page 889: ...afety pin 1 out and fold the two halves of the weight back together Make sure the safety pin locks into place and the two halves of the weight are securely attached to each other If two hoist ropes are reeved you must also place a lifting limit switch weight around the second hoist rope H If you place the lifting limit switch weight around the last rope line leading upwards less rope will run thro...

Page 890: ... around the hoist rope again before driving Removing the lifting limit switch weight Pull the safety pin 1 out and fold the two halves of the weight apart Remove the halves of the weight from the rope line Pull the safety pin 1 out fold the two halves of the weight back together and let the safety pin engage Remove the lifting limit switch weight 2 Remove the lifting limit switch weight on the oth...

Page 891: ... manual 3 302 709 en 12 143 GMK5150L 12 01 2018 Removing the right lifting limit switch Pull out the plug and close the socket with the protective cap 1 Remove the lifting limit switch 4 from the bracket 2 Attach the retaining pin 3 to the lifting limit switch ...

Page 892: ...ggered B Secure the rope 2 in this position using the cap 1 the lifting limit switch is locked Removing the lock You must always release the locking before you place a lifting limit switch weight around the hoist rope A Pull the rope 2 down and take off the cap 1 the locking is released B Fit the cap 1 onto the lifting limit switch S Risk of damage if the lifting limit switch is locked If the lift...

Page 893: ...ns Remove the cable from the holders 2 and connect The anemometer to socket 4 The air traffic control light to the socket 5 Lay the cables in such a way that they will not be damaged during crane operation Check that the anemometer is able to swing so that it hangs vertically even when the main boom is raised s S Risk of damage during on road driving Always remove the anemometer and air traffic co...

Page 894: ...truck crane can be equipped with a switchable air traffic control light This air traffic control light 1 has flashing light and constant light lighting modes Select the desired lighting mode using the switch 2 Switching on off Switch on Select symbol 1 and confirm symbol ON is displayed Switch off Select symbol 2 and confirm symbol OFF is displayed ...

Page 895: ...d with the anemometer air traffic control light before driving on the road Switch off the air traffic control light Remove the plug and close the sockets 5 and 4 with the protective caps Wind the cables on to the clamps 2 Take the rod 1 out of clamp 3 For transport Place the rod 1 in the holder 2 Secure the rod 1 using the retaining pins ...

Page 896: ...Rigging work 12 10 Rigging work on the main boom 12 148 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 897: ... before driving Folding out Release the bolt 1 Fold the railings out until the latches 2 and 3 engage Folding in Release the bolt 3 Pull the locking bar 2 and fold in the railing until the locking bar 1 engages G Risk of accidents if railings are not pushed out The railings provide protection from falling Always fold out the railings before stepping on to the turntable G Risk of accidents due to e...

Page 898: ...rstructure A Folding out and adjusting the mirror Fold out the mirror 1 Adjust the mirror 1 so that the rear right outrigger beam can be observed clearly from the crane cab when the main boom is raised Folding in the mirror Fold in the mirror 1 until it does not protrude over the side of the carrier G Risk of accidents due to exceeding the permissible dimensions Fold the mirror in for driving The ...

Page 899: ...onal safety equip ment or use an authorised fall protection device Fall protection device A Lower the main boom Sling the fall protection device 2 at the point 1 Guide the safety cable 3 to point 4 and fasten it Make sure that the abseiling function on the fall arrester is activated B Raise the main boom and switch all power units off Now connect the safety cable 3 to your per sonal safety equipme...

Page 900: ...smitter nor the receiver should be removed or installed they remain together on the truck crane at all times In the event of a defect both transmitter and receiver must always be replaced even if only one part is defective When spare parts are ordered both transmitter and receiver are always delivered together Switch off the ignition in the crane cab G Risk of accidents if an incorrect transmitter...

Page 901: ...nsert the camera 2 into the clamp 1 and secure it with the retaining pin Insert the plug 4 into socket 3 Lay the cable 5 so that it will not be damaged The camera and the connecting cable Insert the camera 2 into the clamp 1 and secure it with the retaining pin Insert plug 3 in socket 4 Lay the cable 5 so that it will not be damaged s G Risk of accidents due to falling camera Always use a retainin...

Page 902: ...et 3 and close it with the cap Remove the camera 2 from the clamp 1 and put the retaining pin in the holder 1 Wind the cable 5 on to the clamp The camera and the connecting cable Withdraw the plug 3 from the socket 4 and close it with the cap Remove the camera 2 from the clamp 1 and put the retaining pin in the holder 1 Wind the cable 5 on to the clamp ...

Page 903: ...nd the camera symbol 3 B For crane operation you must retract the camera symbol 2 Camera on the driver s cab A camera 1 allows viewing of the non visible area in front of the driver s cab Depending on the version the camera image is shown on the CCS display or on a separate monitor Adjust the camera 1 to show the area 2 in front of the bumper on the display or monitor s G Risk of accidents due to ...

Page 904: ...separate monitor Switching on Switch on the ignition A Select and confirm the symbol 1 or B Press the button 3 once The lamp 4 lights up The image appears on the display after a few seconds Switching the representation A with symbol 1 or B with the buttons or If no image appears à p 14 17 Switching off A Press the button 1 or 2 once or B Press the button 3 once The image will disappear ...

Page 905: ...cab menu Select extend retract access ladder as neces sary 1 Extending Select and confirm the symbol 3 the step extends Retracting Select and confirm the symbol 2 the step retracts On the outrigger control unit Extend Press the buttons 1 and 3 the step extends Retract Press the buttons 1 and 2 the step retracts G Risk of accidents by exceeding the permissible overall width Always retract the step ...

Page 906: ...Rigging work 12 11 Other rigging work 12 158 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 907: ...den planks on it G Risk of accidents due to partially obstructed view of the truck crane When driving the truck crane always stay in visual or radio contact with a banksman who can observe the parts you are unable to see for example the raised main boom in the 0 to the rear position G Risk of overturning by slewing superstructure When driving the rigged truck crane the slewing gear must be switche...

Page 908: ... S Risk of damage to the axle lines Only bring the superstructure and the main boom into the specified posi tions This prevents excessive strain on the axle lines G Risk of accidents if the RCL is overridden Always confirm the current rigging mode The specified positions are within the monitored operating ranges If the RCL is overridden the truck crane may overturn even if you move it into the pos...

Page 909: ... 16 0 35 3 13 0 28 7 21 7 47 840 50 50 0 0 0 20 front 16 0 34 2 14 0 30 9 0 0 0 0 0 70 rear 15 0 33 1 15 5 34 2 24 0 52 911 50 50 0 0 0 20 front 15 0 33 1 15 5 34 2 0 0 0 0 0 70 rear 15 0 33 1 16 0 35 3 26 3 57 982 50 50 0 0 0 20 front 14 5 31 9 16 5 36 4 0 0 0 0 0 65 rear 15 5 34 2 15 5 34 2 30 9 68 123 50 50 50 0 0 20 front 15 5 34 2 17 5 38 6 0 0 0 0 0 65 rear 17 5 38 6 16 0 35 3 44 5 98 106 50...

Page 910: ...Driving with a rigged truck crane 13 2 Permissible rigging modes and axle loads 13 4 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 911: ...to Lifting capacity table for the current Free on wheels 0 to the rear working position Tie down the load so that it cannot swing back and forth Before driving with a load observe the specifications in the relevant section à Driving from the crane cab p 13 17 G Risk of accidents when driving with a lifted load When driving with a lifted load you must be able to operate the crane at any time in the...

Page 912: ...s and axle loads 13 6 3 302 709 en Operating manual GMK5150L 12 01 2018 13 2 3 Axle loads The axle loads do not exceed 25 0 t 55 116 lbs if the main boom is within the permissible working range in a permissible Lifting capacity table Free on wheels working position ...

Page 913: ...st be green s S Risk of damage to the tyres Only drive the rigged truck crane if the tyres are at the prescribed pressure level Never reduce the tyre pressure in order to increase the bearing surface of the tyres G Risk of accidents due to excessively high wind speeds You may not drive the rigged truck crane if the wind speed exceeds the maximum permissible values specified in Lifting capacity tab...

Page 914: ...are just above the ground Lowering wheels Use the Raise axle function to lower all wheels to the ground à Operating the axle raising system p 12 66 G Danger of overturning if the supporting cylinders are retracted unevenly Retract the supporting cylinders evenly This prevents the truck crane overturning while retracting individual outrigger cylinders S Risk of damage to the axle lines Retract the ...

Page 915: ...the marking 1 must be in the middle of the 1 measuring range The displays 2 must show an even axle load à Operating the axle raising system p 12 66 To secure the truck crane Retract the supporting cylinders until the outrigger pads are about 5 to 10 cm 2 to 4 in above the ground Allow the outrigger beams to extend as far as possible G Danger of overturning if outriggers are retracted Always leave ...

Page 916: ...ff p 5 16 Now lower all wheels to the ground G Danger of overturning by unevenly retracting the outrigger cylinders Retract the outrigger cylinders evenly This prevents the truck crane from overturning while retracting individual outrigger cylinders S Risk of damage to the axle lines Retract the outrigger cylinders evenly This prevents excessive strain on the axle lines G Danger of overturning whe...

Page 917: ... is the only one illuminated in the measuring range 1 Switching off the suspension Switch off the suspension the symbol must be red à Switching the suspension on off p 5 16 To secure the truck crane Retract the supporting cylinders until the outrigger pads are about 5 to 10 cm 2 to 4 in above the ground Allow the outrigger beams to extend as far as possible G Danger of overturning if outriggers ar...

Page 918: ...Driving with a rigged truck crane 13 3 Before driving the rigged truck crane 13 12 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 919: ...fferential locks à p 5 51 switch on the transverse differential locks à p 5 51 G Risk of accidents when driving the truck crane from the driver s cab with a lifted load With a lifted load drive the truck crane only from the crane cab You must be able to carry out crane movements in an emergency at all times S Risk of damage to the steering linkage Always switch on separate steering before driving ...

Page 920: ...must realign the truck crane using Raise axle as described in the section Putting the truck crane on the wheels with Raise axle function à p 13 8 S Risk of damage to the steering linkage The steering linkage can be damaged if the steering wheel is moved while the vehicle is stationary S Risk of damage to the axle lines The suspension struts could be damaged if the maximum permissible operation pre...

Page 921: ...tch separate steering off after driving à p 5 63 Engage the parking brake Support the truck crane with the outrigger span required for the job according to the Lifting capacity table and raise until none of the wheels touches the ground Enabled outrigger spans For the Standard slewing range type à p 12 32 For the MAXbase slewing range type à p 12 36 ...

Page 922: ...Driving with a rigged truck crane 13 4 Driving from the driver s cab 13 16 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 923: ...ng Start away slowly so that the hook block load does not swing G Risk of accidents due to partially obstructed view of the truck crane While driving always stay in visual or radio contact with a banksman who can observe the parts which you cannot see such as the erected main boom G Risk of overturning by slewing superstructure When driving the rigged truck crane the slewing gear must be switched ...

Page 924: ...2 In the driver s cab The ignition key must be in position 1 so that the steering cannot block The driver s cab must be locked with the second ignition key in order to secure it against unauthorised use e g braking The parking brake is engaged In the crane cab The ignition must be switched on The hand held control must be disconnected and bridging plugs plugged into all the sockets The superstruct...

Page 925: ...s grey Selecting the operating mode The available operating modes are Crane operation and Driving Crane operation Symbol 1 green symbol 2 white In this operating mode you can perform crane operation in exactly the same way as when the Driving menu is closed This operating mode is selected when the menu is opened Driving Symbol 1 white symbol 2 green In this operating mode the operating elements fo...

Page 926: ...e buttons 4 are assigned the High speed function The crane s hydraulic system Driving mode is switched off symbol 6 grey The engine speed for crane operation is regulated using the pedal 5 In driving operation The symbol 2 is green The transmission is in neutral position display 1 The operating elements 3 are released The buttons 4 are assigned the Steering function The crane s hydraulic system Dr...

Page 927: ...on describes only how to close the Driving menu If you want to stop driving à After driving p 13 32 Apply the parking brake Press button 3 down once lamp 2 lights up Switch to crane operation mode Select symbol 1 and confirm symbol is white Close the Driving menu Press button 4 or 5 once 1 Arrow orange crane s hydraulic system Driving mode on The transmission mode RM DM or neutral position N is se...

Page 928: ...rcle The steering direction is Steering wheel Turn to the right Press button 1 to the right steering wheel turns to the right with right control lever Turn to the left Press button 1 to the left steering wheel turns to the left with right control lever In the rear semi circle The steering direction can be switched between Steering wheel and Reversed The current steering direction is displayed With...

Page 929: ...he desired symbol H All illustrations and descriptions in the following sections refer to the steer ing direction Steering wheel When you switch to the Reversed steering direc tion remember that the wheels will turn in the opposite direction Displays when steering The current steering angle of the wheels is displayed The symbols show the current steering angle s 1 Steering direction Steering wheel...

Page 930: ...maller Crab travel mode When separate steering is switched on you can turn the wheels of the front and rear axle lines in the same direction the truck crane drives sideways Switching to separate steering Select and confirm the symbol for the desired steering mode The symbol 4 indicates the selected steering mode for example Driving around corners If the error symbol is displayed contact Manitowoc ...

Page 931: ...er the steering angle on the 1st and 2nd axle lines and automatically steer the wheels of the 3rd and 5th axle lines A When driving around corners The 3rd to 5th axle lines are always steered to suit the turning radius The 3rd axle line is steered in the same direction as the 1st and 2nd axle lines The 4th and 5th axle lines are steered in the opposite direction to the 1st and 2nd axle lines B For...

Page 932: ...h axle lines with the button 2 The axle lines are steered as long as you keep the button pressed or until an end position is reached A For driving around corners Steer the 3rd and 5th axle lines in the oppo site direction to the 1st and 2nd axle lines B For crab travel mode Steer the 3rd and 5th axle line in the same direction as the 1st and 2nd axle line To turn to the left Press buttons 1 2 to t...

Page 933: ... to the Straight ahead position the current wheel position is displayed Select and confirm the symbol 3 display symbol 4 If the error symbol is displayed contact Manitowoc Crane Care à p 8 24 Steering in normal steering mode The 2 symbol is displayed Steer the 1st and 2nd axle lines with the button 1 The wheels of the 3rd to 5th axle lines are turned correspondingly for driving around the corner T...

Page 934: ...h Transmission modes with crane functions Switch to transmission mode DM or RM The crane s hydraulic system Driving mode is switched on symbol 1 orange The transmission shifts only into the 1st gear reverse or forwards The speed is limited to about 5 km h 3 mph In these transmission modes you can start moving more slowly than in the transmission modes D or R These transmission modes are intended f...

Page 935: ...e D The speed is limited to a maximum of about 20 km h 12 mph 5th gear maximum Use this transmission mode only when The main boom is completely retracted The main boom is resting in the boom rest The outrigger beams cylinders are fully retracted Warning messages If a symbol is shown in area 1 à Warning messages on the CCS display p 14 3 à Error messages on the CCS display p 14 8 G Risk of accident...

Page 936: ...ing state Longitudinal transverse differential locks With a 10 x 8 x 10 drive the drive of the 3rd axle line is switched on and off together with the longitudinal differential locks Straighten the steering Stop the truck crane For switching on and off the current speed needs to be under about 5 km h 3 mph S Risk of damage to the differential locks Leave the transverse differential locks switched o...

Page 937: ...ifferential locks B Start moving slowly display First symbol 2 yellow then symbol 3 red differential locks on 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 If the error symbol is displayed con...

Page 938: ...ngitudinal differential lock 3 Switch off transverse differential locks 2 Switch on normal steering mode 4 Press button 7 down once The lamp 6 lights up symbol 5 is red the parking brake is applied If necessary switch the engine off à Switch off the engine p 10 11 Remove the ignition key from the ignition lock in the driver s cab and lock the driver s cab to prevent unauthorised access Put the tru...

Page 939: ...ing the emergency stop switch p 4 19 H The battery master switch cannot be used as an emergency stop switch for the engine The engine continues to run after the battery master switch has been switched off G Risk of overloading if used improperly Press the emergency stop switch only if it is no longer possible to stop the crane movements with the normal operating elements The emergency stop switch ...

Page 940: ...emergency operation with the hand pump p 14 51 Lock the truck crane to prevent unauthorised use Remove the ignition key and lock away the hand held control Inform your supervisor Try to eliminate the malfunction Inform Manitowoc Crane Care if you cannot correct the malfunction Load cannot be set down Secure the danger area using cordons and warning signs Notify Manitowoc Crane Care G Risk of accid...

Page 941: ...e serial number after a malfunction occurs before notifying Manitowoc Crane Care Open the Program version menu 1 14 3 1 Warning messages on the CCS display If the CCS detects a malfunction then a symbol is shown in the display area for example the symbol 1 If several warning messages exist all of the corresponding symbols are displayed one after the other in consecutive order s 1 Serial number dis...

Page 942: ...off the ignition and wait about 15 seconds then switch it on again If the malfunction is still present contact Manitowoc Crane Care Engine oil pressure Switch off the engine as quickly as possible Check the engine oil level and top up with oil if necessary à Maintenance manual If the oil level is correct then start the engine from the driver s cab and check the warning messages that are present S ...

Page 943: ...play of the current temperature à p 10 8 Possible cause and remedy à p 14 22 Replace hydraulic oil filter Replace the corresponding hydraulic oil filter as soon as possible à Maintenance manual Slewing gear brake too hot Stop crane operation as soon as possible and let the slewing gear brake cool down Anemometer not connected Connect the anemometer to the electrical power supply à p 12 145 Voltage...

Page 944: ...sion the counterweight The pre tensioning pressure is too low Pre tension the counterweight à p 12 105 Slewing disabled by counterweight The pre tensioning pressure is too low or the counterweight is not completely lifted Pre tension the counterweight à p 12 105 Reduction of slewing speed switched off Blue information The slewing speed is not reduced automatically Red warning The maximum permissib...

Page 945: ...epeat the procedure if necessary If the sybol is still displayed then start the engine from the cab and carry out a few gear changes in the transmission If the symbol continues to be displayed please contact Manitowoc Crane Care Emergency stop switch actuated à Resetting the emergency stop switch p 4 19 Vehicle brake Stop the truck crane immediately and check the pressure in the brake circuits à p...

Page 946: ...or menu 3 For the subsequent procedure à p 8 17 2 Crane operation error The buzzer tone sounds once Open the Crane operation error menu 4 Display of error total errors Display 3 shows the error total and display 2 shows which error is displayed 3 5 for example means Error 3 is shown A total of 5 errors are pending Displaying errors The rotating symbol 1 indicates that further unacknowledged errors...

Page 947: ...e error If the error cannot be acknowledged consult Manitowoc Crane Care Error message display For each error the display shows The error code 5 The symbols for Exiting the menu You can exit the error menu at any time via button 1 or 2 If not all errors have been acknowledged then the symbol 1 will be displayed continuously When all errors are acknowledged the symbol 1 goes out The buzzer tone sou...

Page 948: ...g gear p 9 120 Main boom angle too large Lower the main boom à Derricking gear p 9 120 S Risk of damage if warning messages are disregarded Observe the following information in good time and take the appropriate remedial measures if a warning message appears This prevents these malfunctions causing defects in the truck crane G Risk of accidents due to overridden or faulty RCL Only override the RCL...

Page 949: ... operating manual Lattice extension angle too large Lower the lattice extension à Lattice extension operating manual Boom extension angle not measured different sensor values Main boom lifting capacity table not present Lattice extension lifting capacity table not present RCL override switch 1 not actuated RCL override switch 1 actuated RCL override switch 2 not actuated RCL override switch 2 actu...

Page 950: ...override switch 3 actuated RCL override all switches actuated Learn in phase Displayed only during maintenance by service personnel Data acquisition Displayed only during maintenance by service personnel Lattice extension maximum permissible load exceeded Load too low RCL error status display Active working range limiter maximum permissible overall height reached ...

Page 951: ...lewing angle reached Active working range limiter maximum permissible working radius reached Hoist rope travel limitation upper or lower limit reached Hoist rope travel limitation working radius or telescope status changed If the described measures do not solve the problem try to remedy the error by switching off the ignition and switching it on again after about 15 seconds ...

Page 952: ...Malfunctions during crane operation 14 3 Warning and error messages 14 14 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 953: ...ed Engine malfunction à Malfunctionsontheengine p 8 19 Malfunction Cause Solution Main hoist not working or malfunctioning Main hoist off lamp in but ton lights up dimly à Switching on the main hoist p 11 76 à Switching on the auxiliary hoist p 11 79 Dead man s switch not actuated Press dead man s switch Emergency stop switch on à Resetting the emergency stop switch p 4 19 Control unit fuse blown ...

Page 954: ...t working Function disabled by CCS If required acknowledge error message once and briefly turn off the ignition it if occurs again notify Manitowoc Crane Care No lift function Control unit fuse blown Replace the blown fuse à p 14 75 Lifting or lowering is either not possible at all or only at a low speed Speed limited Increase limit à p 11 125 Lifting or lowering function cannot be switched off CC...

Page 955: ...een camera and monitor is disconnected Check cable connection and notify Manitowoc Crane Care if necessary Extendable tripod not working Fuse F7 5 blown Replace blown fuse à p 14 75 Malfunction Cause Solution No image appears on the monitor after it is switched on Fuse F6 8 blown Replace blown fuse à p 14 75 Fuse blown in camera or monitor Check fuses and replace as necessary à Manufacturer operat...

Page 956: ...notify Manitowoc Crane Care Lowering function not working Lifting limit switch approached lamp lights up Leave the shutdown range and lower the auxiliary hoist RCL shutdown lamp lights up Leave the shutdown range à p 11 58 Control unit fuse blown Replace the blown fuse à p 14 75 Derricking function not working Function disabled by CCS If required acknowledge error message once and briefly turn off...

Page 957: ...towoc Crane Care Extending function not working Control unit fuse blown Replace the blown fuse à p 14 75 RCL shutdown lamp lights up Leave the shutdown range à p 11 58 Lifting limit switch approached lamp lights up Leave the shutdown range retract boom Retracting function not working Insufficient lubrication Lubricate main boom à Maintenance manual Main boom is not steep enough Leave the shutdown ...

Page 958: ...oning Slewing gear off lamp in button lights up dimly Switch on the slewing gear à p 11 116 Superstructure locked Unlock superstructure à p 11 15 Dead man s switch system not engaged Press dead man s switch Emergency stop switch on à Resetting the emergency stop switch p 4 19 Control unit fuse blown Replace the blown fuse à p 14 75 Control unit faulty error message is displayed Acknowledge error m...

Page 959: ... 360 Standard or reduce the working radius MAXbase or slew in the opposite direction to leave the shutdown angle Slewing not possible or only at low speed Speed limited Increase limit à p 11 125 Slewing gear no longer responds to the control lever movement CCS malfunction Emergency stop switch à p 14 1 No response to control lever movements CCS malfunction for operating elements in the crane cab U...

Page 960: ...Care Electronic system has detected an electrical or logical error Extend lifting cylinder not working Superstructure unlocked à Lock the superstructure p 11 16 Malfunction Cause Solution Hydraulic oil temperature above 80 C 176 F fan in the hydraulic oil cooler running Hydraulic system is heavily loaded Stop the crane operation and keep the engine running until the oil has cooled down Hydraulic o...

Page 961: ...lown fuse à p 14 75 Pre selected function can not be performed Another function has been pre selected Pre select the desired function Operation not possible Malfunction in the control system Inform Manitowoc Crane Care Malfunction Cause Solution Crane cab inclination function not working Control unit fuse blown Replace the blown fuse à p 14 75 Malfunction Cause Solution The menu cannot be opened S...

Page 962: ...idging plug not inserted Parking brake not applied Slewing gear switched on Disconnect hand held con trol or insert bridging plug à p 12 25 Lock the parking brake à p 5 46 Switching the slewing gear off à p 11 120 When operating from the control units Display fields switched off Switch on display fields à p 12 45 Hand held control con nected to the superstruc ture or a bridging plug not inserted D...

Page 963: ...flashes yellow Ambient temperature too high Cool the crane cab Display weak Ambient temperature too high brightness is reduced automatically The set brightness is restored after cooling Malfunction Cause Solution The transmission the dif ferential locks and the separate steering do not respond to the operating elements symbols grey Parking brake applied Releasing the parking brake à p 13 18 Igniti...

Page 964: ...he bolts 2 and remove the cover 1 Check the associated fuse on the plate 3 and replace it if necessary à Fuses in the crane cab p 14 75 Loosen the screws 4 and fold down the plate 3 to the front S Risk of damage if procedure is incorrect Observe the following notes to avoid malfunctions and damage Always switch the ignition off before changing a fuse and before checking the antenna plugs Replace b...

Page 965: ...l 3 302 709 en 14 27 GMK5150L 12 01 2018 Check the fuses 1 and replace them if necessary Check whether the plugs 2 are plugged in After checking Fold the plate 3 up and secure it with the screws 4 Fasten the cover 1 using the bolts 2 Designation Amperage F3401 5 A F3402 5 A ...

Page 966: ...Malfunctions during crane operation 14 4 Troubleshooting 14 28 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 967: ...operations and programs This section contains all the information about possible emergency operations and emergency programs The following are available Mechanical emergency activation for retracting The Telescoping emergency program menu Entering the telescoping after an emergency operation Operation of the power units with the hand held control ...

Page 968: ... confirm the current rigging mode of the truck crane The current rigging mode must be shown on the RCL display Lower the main boom If the RCL allows the boom to be lowered into a horizontal position You can reach the locking points with a ladder and need only one auxiliary crane to telescope the unlocked telescopic sections If the RCL is deactivated prior to reaching the horizontal position In ord...

Page 969: ...d at a locking point the correspond ing telescopic section cannot be locked or unlocked manually There are two M8 x 110 bolts for every telescopic section These bolts are in the toolbox supplied with the crane You will need a suitable tool 3 at least 250 mm 9 8 in long In order to unlock the telescopic section screw the bolts 4 into the bores 1 in the locking pins Pins located further inside are r...

Page 970: ...opic section as well Locking the telescopic section A Retract the telescoping until the locking pin 2 is in the middle of the opening Unscrew the bolt from the bore 1 until the locking pin 2 is fully extended Remove the bolt from the bore 1 B Retract the telescoping further until the telescopic section is set down S Risk of damage due to a mechanically released lock Under no circumstances may you ...

Page 971: ... amount of time Telescoping emergency program menu If possible set down the load before starting the emergency program à What to do when malfunctions occur during crane operation p 14 2 Select and confirm the symbol 1 the Telescoping emergency program is opened Select and confirm the symbols 1 to 4 Confirm the entry with the symbol 5 You can cancel the entry at any time using the 6 or 7 buttons On...

Page 972: ...ity switch The symbols 4 and 5 are active After selec tion and confirmation locking or unlocking is performed immediately G Risk of damage to the telescoping mechanism Ensure that you always have an overview of the current status of the tele scoping mechanism before you initiate locking or unlocking In emergency mode there is no monitoring of prerequisites the function is performed immediately aft...

Page 973: ...egister the current status of the telescoping mechanism Check the positions of the locking pins as usual i e at the symbols 1 and 2 Check that the display 3 shows the RCL measured value for the extended length of the telescoping cylinder s G Risk of damage to the main boom Never telescope the main boom if at the same time there is an error at both the length indicator and the proximity switch It w...

Page 974: ... locking a telescopic section During telescoping you may not select Lock Under no circumstances should you select and press the symbol 1 G Risk of accidents from sudden retraction of a telescopic section You can select and confirm the symbol for unlocking the telescopic section only a maximum of 2 times If this does not start the unlocking procedure contact Manitowoc Crane Care S Risk of damage to...

Page 975: ... as far as it will go Unlocking the telescoping cylinder If the telescopic section 1 is locked you can now unlock the telescoping cylinder Select and confirm the symbol 1 The telescoping cylinder is unlocked display symbol 3 locking pin 2 red You can now move the telescoping cylinder into the next telescopic section à Locking points for the telescoping cylinder p 14 39 s G Risk of accidents from s...

Page 976: ...ylinder into the next extended telescopic section At the locking point the display 3 shows the length for the current locking point à p 14 39 Select and confirm the symbol 1 The telescoping cylinder is locked display symbol 4 locking pin 2 green You can now retract this telescopic section à p 14 36 S Risk of damage to the main boom If you select Lock while the telescoping cylinder is moving the lo...

Page 977: ... table shows the extended length for locking the telescoping cylinder s Table for locking the telescoping cylinder Telescopic section Locking point at fixed length Extended length of telescoping cylinder in in mm in ft Telescopic section I 0 56 89 100 5 5 226 8 453 9 497 0 02 17 15 27 73 31 16 Telescopic section II 0 53 89 100 285 5 543 8 793 9 845 0 94 18 19 28 85 32 30 Telescopic section III 0 5...

Page 978: ... length for locking and unlocking the telescopic sections Table for locking unlocking the telescopic sections Telescopic section Locking point at fixed length Extended length of telescoping cylinder in in mm in ft Telescopic section I 0 56 89 100 30 5 251 8 478 9 522 0 10 13 11 27 81 31 24 Telescopic section II 0 53 89 100 310 5 568 8 818 9 870 1 02 18 27 28 93 32 38 Telescopic section III 0 52 89...

Page 979: ...ping e g the values from the RCL display Select and confirm the symbol 1 the Unknown telescoping menu is opened Select and confirm the symbols 1 to 4 Confirm the entry with the symbol 5 You can cancel the entry at any time using the 6 or 7 buttons After the correct input the area for the set value input will be opened Entering target values Select and confirm the symbols 1 to 5 Enter the desired t...

Page 980: ...1 2018 You can cancel the entry at any time using the 1 or 2 buttons S Risk of damage due to incorrect input Before working with the crane check whether CCS indicates the current telescoping and correct if this is not the case Entering incorrect values causes malfunctions and may result in damage to the telescoping mechanism ...

Page 981: ...ded for emergencies only and for bringing the truck crane into a safe state or to shut it down Connect the hand held control Connect the hand held control to the connector 1 All power units can be operated from this connection Information on connecting à p 12 25 Starting the engine Press the button 1 once the engine will start à p 10 10 s G Danger of overturning due to deactivated monitoring funct...

Page 982: ...ain hoist press button 1 first and then also button 2 The further you press button 2 the quicker the movement The maximum speed is limited to about 50 for all power units The table shows all the button combinations Engaged buttons are shown in black G Danger of overturning when moving into the shutdown ranges Avoid lowering the boom If you cannot avoid lowering try to set down the load beforehand ...

Page 983: ...s The movement continues until you release the button or the end position is reached s Pre selected power unit Button combination Telescoping mechanism Derricking gear Slewing gear Hoist Lattice extension c e f a d No Lower Lock turntable Lowering Lower Retract Raise Unlock turn table Lifting Raise No No Slew to right No No No No Slew to left No No ...

Page 984: ...4 19 Switch off the engine You can switch off the engine only by using the hand held control Stop all crane movements Press the button 1 the engine will switch off 14 5 5 Notes on slewing in emergency operation For the Standard slewing range type If the MAXbase slewing range type is activated à p 14 48 Slewing is not monitored by the RCL in emergency operation G Risk of overturning when slewing in...

Page 985: ...2 205 lbs 3 3 t 00 lbs Slewing not permissible2 5 6 t 12 346 lbs 7 9 t 17 417 lbs Slewing not permissible3 10 2 t 22 487 lbs Slewing 12 5 t 27 558 lbs permissible1 14 8 t 32 628 lbs 17 1 t 37 699 lbs 19 4 t 42 770 lbs 21 7 t 47 840 lbs 24 0 t 52 911 lbs 26 3 t 57 981 lbs 30 9 t 68 123 lbs 44 5 t 98 106 lbs 1 Slewing permissible only if the working radius permissible in the working range is observe...

Page 986: ...ity table are correctly shown on the RCL display Slew slowly towards a safe range and check that the current position 1 changes accordingly Derrick slowly towards a safe range and check that the current position 1 changes accordingly If the RCL display still displays correctly You can use the RCL display for orientation while slewing and correct the working radius before reaching the slewing range...

Page 987: ...s Press the button 2 in at the top The lamp 1 lights up The lifting limit switch is overridden Slewing in permissible working range will be released The slewing speed is limited to about 6 Cancelling the override Release button 2 The lamp 1 goes out The lifting limit switch override is cancelled The slewing will be blocked if the shutdown is still pending S Risk of damage due to overridden slewing...

Page 988: ...Malfunctions during crane operation 14 5 Emergency operations and programs 14 50 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 989: ...perate the derricking gear and perform the Lower main hoist movement for example to raise the main boom in the case of a defective engine The hand pump 1 which is activated by switching over a valve is used as the energy source for the crane s hydraulic system The hydraulic circuits are switched via the valves 2 The crane movements are performed by operating the hand pump G Danger from mutual inte...

Page 990: ...tion you can open tap 4 at the beginning of the operation as described in this section this leads to the elimination of this step later during emergency operation This does not affect the emergency operation of the other power units For crane operation Open the valve 4 and secure it using the lock 2 Close the valve 5 and secure it using the lock 1 For emergency operation Take off the lock and clos...

Page 991: ...ecuring valves Releasing securing is described for a valve The procedure is identical for valves 1 to 3 Release for the emergency operation Unscrew the handle 1 Move the disc 2 to position A Fasten the handle 1 Rigging for crane operation The valve must be closed Unscrew the handle 1 Move the disc 2 to position B Fasten the handle 1 s S Danger due to operating error Following emergency operation s...

Page 992: ...3 For emergency operation Unlock the valves 1 2 and 3 à p 14 53 Switch the valves 1 to 3 to the positions for the desired crane movement as shown in the following table For lowering for example switch the valve 2 outward valve open Valves 1 and 3 must be switched forwards Emergency operation for crane movement Valves outward Valves to the front Additional switching operations Lowering 3 1 2 Valve ...

Page 993: ...valve Y1104 Lowering 1 Remove the plug 4 Screw the cap with pin 3 on to the valve continuous operation is now switched on Switching off continuous operation Unscrew the cap 2 from the valve 1 Screw the cap on so that the pin 3 can be seen Insert the plug 4 S Danger due to falling loads Switch off continuous operation immediately after emergency activation Check that the pin can be seen on the cap ...

Page 994: ...ual GMK5150L 12 01 2018 14 6 4 Performing emergency activation If the required hydraulic circuit has been established you can make the corresponding crane movement using the hand pump 1 Insert the pump lever 2 provided into the holder at the hand pump lever Pump with the lever the corresponding crane movement is performed ...

Page 995: ... restore the truck crane to its original state after finishing emergency activation After each emergency activation Switch valves 1 to 3 to crane operation à p 14 54 Switch the valve 5 to crane operation à p 14 52 Switch the valve 4 to crane operation à p 14 52 Remove the lever from the hand pump Additionally after the lowering Switch off continuous operation on the valve Y1104 à p 14 55 ...

Page 996: ...Malfunctions during crane operation 14 6 Hydraulic emergency operation with the hand pump 14 58 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 997: ...hoist derricking gear and slewing gear The energy source for the crane hydraulics is a transformer 1 which is driven by the car rier s hydraulic system in case of self suffi ciency or is driven by a hydraulic external energy source in case of an external power supply The hydraulic circuits are switched via the valves 3 The control lever 2 is used to control the direction of movement and the speed ...

Page 998: ...nual GMK5150L 12 01 2018 Emergency supply You can supply another crane that also has an hydraulic emergency operation according to BGR 159 In the event of emergency supply the connec tions 1 feed a transformer 2 which is con nected to the hydraulic system of the other crane à Emergency supply of another crane p 14 73 ...

Page 999: ...e the warnings and safety instructions specified here 1 For emergency operation with self sufficiency Attach and connect the transformer to the superstructure à p 14 63 Switching on emergency operation à p 14 65 2 For emergency operation with external energy source Attach and connect the transformer to the superstructure à p 14 66 3 Establishing the required hydraulic circuits à p 14 67 Carrying o...

Page 1000: ...ety instructions specified here 1 Switching off emergency operation After emergency operation with self sufficiency à p 14 65 After emergency operation with external energy source àOperating manual of energy source 2 Establish hydraulic energy circuit for the crane operation Switch valves 1 to 5 into position for crane operation à p 14 67 Switching off continuous operation à p 14 69 Open valve 6 à...

Page 1001: ...e off Connecting The hoses are assigned according to the various diameters On the carrier Attach the transformer 3 to the super structure Connect the hoses 2 to the connections 1 superstructure Connect the hoses 2 to the ports 1 s S Risk of damage to the hoses Lay the hoses in such a manner that they can be moved freely so as to pre vent them being crushed or torn or becoming caught during subsequ...

Page 1002: ...12 01 2018 Removing After the emergency operation you must disconnect the hoses and the transformer On the superstructure Remove the hoses 2 from the ports 1 Close off the hoses and connections with the caps On the carrier Remove the hoses 2 from the ports 1 Close off the hoses and connections with the caps Remove the transformer 3 ...

Page 1003: ...02 709 en 14 65 GMK5150L 12 01 2018 14 7 5 Switching emergency operation on off Switching on Start the engine Select and confirm the symbol 1 Display symbol 2 emergency operation switched on Switching off Select and confirm the symbol 2 Display symbol 1 emergency operation switched off Switch the engine off ...

Page 1004: ...e assigned according to the various diameters Switch off the hydraulic energy source Attach the transformer 3 to the super structure Connect the hoses 2 to the connections 1 Connect the hoses 4 to the supplying energy source Switch on the hydraulic energy source Removing Switch off the hydraulic energy source Remove the hoses 2 from the connec tions 1 Remove the hoses 4 from the supplying energy s...

Page 1005: ...ablish a hydraulic circuit H The valves 1 to 5 for hydraulic emergency operation with the hand pump must be switched to Crane operation Check the positions of the valves and if necessary switch to Crane operation à Switching over valves p 14 54 à Switching over the crane s hydraulic system p 14 52 Valves at the control panel The valves 1 to 5 are labelled with their respective numbers For crane op...

Page 1006: ...ane operation always switch all the valves 1 to 5 down This prevents the power units suddenly starting to move G Danger from mutual interference of the power units For one crane movement always switch valves upward This prevents wrong crane movements being performed and several movements being performed unintentionally at the same time Emergency operation for crane movement Valves upwards Valves d...

Page 1007: ...ap 3 e g off valve 1 Remove the plug 5 Screw the cap with pin 4 on to the valve continuous operation is now switched on Switching off continuous operation Remove the cap 3 from the actuated valve 1 2 Screw the cap on so that the pin 4 can be seen Insert the plug 5 s 1 Valve Y1104 Lowering or 2 Valve Y1105 Lifting S Danger due to falling loads Switch off continuous operation immediately after emerg...

Page 1008: ...02 709 en Operating manual GMK5150L 12 01 2018 For slewing After switching over the valves behind the crane cab you must also close a valve A Emergency operation position Close the valve 6 lever 1 at right angles to the line B Crane operation position Open the valve 6 lever 1 parallel to the pipe ...

Page 1009: ...he control lever in the crane cab Slowly move the control lever 1 in the required direction s G Risk of overturning when slewing in emergency operation Crane operations are not monitored by the RCL whilst the hand held control is connected Various checks are therefore necessary depending on the active slewing range type before slewing in emergency operation à p 14 46 G Risk of accidents during sle...

Page 1010: ...necessary Move the control lever 1 in the required direction Lifting lowering Move the control lever 1 in the required direction G Danger of overturning if the working radius is too large when lowering the boom In emergency operation operations are not shut down by RCL This also applies if the RCL displays are still active after switching on the ignition The truck crane will overturn if you exceed...

Page 1011: ...lied Attach the transformer 3 Attach the hoses 4 à Operating manual of the other crane On the GMK5150L Switch the engine off Connect the hoses 2 to the connec tions 1 Switch on the hydraulic emergency operation à p 14 65 After emergency supply On the GMK5150L Switch off the hydraulic emergency opera tion à p 14 65 Remove the hoses 2 from the connec tions 1 On the crane that was supplied Disconnect...

Page 1012: ...Malfunctions during crane operation 14 7 Hydraulic emergency operation acc to BGR 159 14 74 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 1013: ...a fuse has to be replaced s S Risk of damage if the ignition is switched on Switch off the ignition whenever a fuse has to be replaced This prevents the new fuse being blown immediately by the increased starting current after being installed S Risk of damage by overloading Replace blown fuses only with new fuses of the same amperage This pre vents parts being overloaded and damaged or the fuse bei...

Page 1014: ...ding their amperage and functions Observe the instructions for fuse changes à p 14 75 The designations 1 to 8 in the tables correspond to their order from left to right fuse 1 is always the left fuse Designation Amperage A Function F1 1 15 Control unit UB 1 CCM 10 F1 2 15 Control unit UB 2 CCM 10 F1 3 15 Control unit UB SCM F1 4 15 Control unit UB IOS 20 F1 5 5 Control unit UB UE IOS 21 F1 6 15 Co...

Page 1015: ... 30 F2 3 15 Control unit UB 2 IOL 30 F2 4 15 Control unit UB 1 IOL 34 F2 5 15 Control unit UB 2 IOL 34 F2 6 15 Control unit UB 2 IOL 34 F2 7 15 Control unit UB 2 IOL 34 F2 8 Unassigned Designation Amperage A Function F3 1 Unassigned F3 2 Unassigned F3 3 Unassigned F3 4 3 Contact switch for cab lighting F3 5 5 CCS display F3 6 5 Hand held control F3 7 7 5 Comfort seat1 F3 8 5 Cigarette lighter 1 Ad...

Page 1016: ... F4 3 3 CraneSTAR system F4 4 10 Radio1 F4 5 Unassigned F4 6 3 Central locking system reserve F4 7 Unassigned F4 8 3 Rotating beacon Designation Amperage A Function F5 1 5 Control unit 15 SCM CCM 10 Control unit UE IOL 30 IOS 22 F5 2 5 Control unit 15 UE IOS 20 and 21 F5 3 3 CCS display F5 4 3 Control lever F5 5 5 Control lever supply F5 6 3 Reserve F5 7 5 Reserve F5 8 5 Switch lighting 1 Addition...

Page 1017: ... 7 3 Radio control F6 8 5 Camera system Designation Amperage A Function F7 1 3 Rotating beacons F7 2 5 Diagnostic connection F7 3 3 Heating system F7 4 3 Extendable step for crane cab F7 5 5 Hoist camera tripod F7 6 Unassigned F7 7 Unassigned F7 8 Unassigned Designation Amperage A Function F8 1 5 Crane control power supply F8 2 3 Crane control power supply F8 3 3 Crane control power supply F8 4 3 ...

Page 1018: ...Malfunctions during crane operation 14 8 Fuses in the crane cab 14 80 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 1019: ...nclear we have not included every single element from the instrument panel Those elements such as switches and buttons lamps and displays are described and named in detail in the overviews of Chapter 3 and Chapter 9 Truck Crane Description From there you are referred as usual to more detailed descriptions of these elements ...

Page 1020: ...Index 15 2 3 302 709 en Operating manual GMK5150L 12 01 2018 Blank page ...

Page 1021: ...ing the connection between the auxiliary hoist and the turntable 6 42 slinging points 6 39 transportation 6 46 lifting and lowering 11 80 short description of the operating elements 9 116 switch off 11 81 switch on 11 79 Axle loads required speed limit 6 6 weighing the truck crane 6 7 Axle loads when driving the rigged truck crane 13 6 B Batteries battery master switch 4 9 Battery master switch op...

Page 1022: ...ements in the crane cab general information menu independent displays 9 18 overview of the menu groups 9 22 start menu 9 19 in menu for outriggers outrigger beams 9 30 outrigger cylinders 9 32 in the driving menu 9 34 in the Settings menu operating hours 11 133 menu group setting units 3 31 menu groups RCL telescope 9 37 on the control unit 9 16 superstructure menu group 9 26 counterweight 9 28 ou...

Page 1023: ... the main boom 6 21 installing the outrigger beams 6 54 removing the main boom 6 18 removing the outrigger beams 6 52 retracting the outriggers 12 43 rigging counterweight 12 77 rigging for crane operation with main boom 12 1 unrigging counterweight 12 79 unrigging for crane operation with main boom 12 7 Checks before driving 5 7 safety equipment 11 10 vehicle height 5 9 Choose a positioning site ...

Page 1024: ...rear window 9 154 standard heating system 11 151 window 9 154 Crane control CCS in the driver s cab overview of the menu groups 3 24 short description of the operating elements 9 95 Crane operation CHECKLIST checks before operating the crane 11 1 permissible slewing ranges 11 21 preheating hydraulic oil 11 14 slewing range type MAXbase 11 23 enabled slewing ranges 11 25 note on outrigger spans wit...

Page 1025: ...air heater 3 19 auxiliary water heating system 3 18 on the CCS display 3 23 on the instrument panel 3 11 on the steering column 3 10 standard heating system 3 17 transmission 3 14 operating elements steering column steering wheel 3 10 overview 3 6 Radio 5 80 tilting and lowering 8 43 8 44 prerequisites 8 43 window 3 74 Driving at low temperatures CHECKLIST 4 4 brakes additional brakes 5 43 checks ...

Page 1026: ...ssible connections 13 30 driving from the driver s cab preparations 13 13 whilst driving 13 14 rigging modes driving with load 13 5 driving without a load 13 5 route 13 1 E Earthing load 11 13 of the truck crane 12 15 Earthing the load 11 13 Electrical system checks in the crane cab 11 7 checks in the driver s cab 5 7 display and operating elements in the crane cab 9 145 operating elements in the ...

Page 1027: ...e engine 4 19 10 12 Emergency stop switch for crane operation 14 1 for driving 8 1 Engine malfunctions 8 19 14 15 operation in the crane cab AdBlue Check the filling level 10 3 checking after starting 10 8 checking the fuel level 10 3 checks before starting 10 4 emergency stop switch resetting 10 12 idling speed setting 10 9 starting 10 7 switching off 10 11 switching the ignition on 10 5 switchin...

Page 1028: ... auxiliary heater fuel level 11 5 Fuses on the carrier 8 49 in the battery box 8 56 in the driver s cab 8 50 on the superstructure in the crane cab 14 75 H Hand held control connect the hand held control 12 25 disconnecting the hand held control 12 25 functionality and positions of the sockets 12 24 malfunctions 14 23 Heating system crane cab auxiliary heater 11 155 standard heating system 11 151 ...

Page 1029: ...ulic emergency operation see emergency operation Hydraulic system carrier checking the valves on the hydraulic tank 4 8 10 4 I Identification of the counterweight sections 12 75 Inclination indicator short description of the operating elements 9 108 Inclination indicators 12 60 Information conversion table for US measuring units 1 33 for operations planning 1 32 notes on the operating manual 1 25 ...

Page 1030: ...ile towing 8 30 Longitudinal differential locks operation from the crane cab 13 30 longitudinal differential locks operation from the driver s cab 5 51 M Main boom removing installing additional equipment required 6 17 aligning the connecting points 6 36 CHECKLIST installing the main boom 6 21 removing the main boom 6 18 disconnecting connecting hydraulics electrical 6 24 extending retracting the ...

Page 1031: ...22 suspension 8 25 telescoping mechanism 14 19 transmission 8 22 8 23 turntable lock 14 24 when driving from the crane cab 14 25 when operating with the hand held control 14 23 Mirror adjusting on the superstructure 12 150 Movement combinations when operating with the main boom 11 122 O Off road driving 5 49 On board computer general operation 3 72 overview 3 15 Ooperating elements in the driver s...

Page 1032: ...g box 6 64 electrical connection 6 61 error messages with removed outrigger beams 6 68 extending retracting the outrigger beam 6 64 hydraulic connection 6 60 preparations for removal 6 56 on truck crane 6 57 removing attaching outrigger pads 6 58 transportation 6 68 unscrewing screwing in the spacers 6 62 levelling the truck crane on outriggers horizontally automatic 12 62 inclination indicators 1...

Page 1033: ...scoping 11 40 RCL early warning 11 57 RCL shutdown 11 57 switching on 11 30 override RCL version A 11 63 override RCL version B 11 67 short description of the operating elements 9 133 warning messages on the RCL display 14 10 Reeving unreeving the hoist rope pocket lock version A 12 124 version B 12 125 reeving the hoist rope 12 127 unreeving the hoist rope 12 131 Remote control short description ...

Page 1034: ...m the crane cab 9 146 S Safe distance from electrical cables 12 16 to slopes and pits 12 14 Safety basic safety instructions 2 1 Instructions on transporting persons 2 10 intended use 2 1 Safety equipment checking 11 10 Seat adjusting crane cab seat 11 8 driver s seat 5 13 passenger s seat 5 14 Separate steering 5 59 steering with separate steering 5 61 13 26 switching to normal steering mode 5 63...

Page 1035: ...eating hydraulic oil 11 14 short description of the operating elements 9 128 Superstructure lock locking unlocking 11 15 see houselock short description of the operating elements 9 129 Suspension locking switching off 5 16 operating elements in the driver s cab 3 64 suspension switching on off 5 16 Switch cameras on off for crane operation 12 152 T Tachograph 5 18 inserting diagram sheets 5 20 tim...

Page 1036: ...h semi automaton 11 110 telescoping CCS display 11 108 Temposet 5 40 Torque reduction see AdBlue system Total weight weighing the truck crane 6 7 Tow starting 8 32 Towing 8 29 after engine transmission damage 8 29 compressed air supply after engine failure 8 29 electric power supply 8 30 parking brake 8 31 towing distance greater than 100 m 8 32 towing the truck crane out of the hazard area 8 32 T...

Page 1037: ... checking the horizontal alignment 11 73 earthing 12 15 overview 9 2 overview of the carrier 3 2 rocking free 5 57 safe distance 11 73 securing against rolling away 5 46 switching off 5 46 towing free forwards 5 58 reverse 5 58 Turntable lock lock turntable 11 16 locking points 11 15 short description of the operating elements 9 129 unlock turntable 11 16 V Vehicle engine diagnostics plug 3 71 Vol...

Page 1038: ...eel change 8 33 Windscreen wiper 3 65 crane cab 9 148 driver s cab 3 65 Windscreen wiper washing system 9 146 Work break in case of short work breaks 11 149 in case of work breaks of more than 8 hours 11 150 Working range limiter menu overview 9 47 operation 11 135 ...

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