PDF Operating Instruction Manual Grove GMK 5200-1 Crane - 5 MB
This is the official operating instruction manual for the Grove GMK 5200-1 all-terrain crane.
It is a critical document for ensuring the safe and proper operation of this advanced lifting equipment.
The manual covers all controls, setup procedures, safety systems, and routine checks.
Every operator must be thoroughly familiar with this content to maximize safety and efficiency on the job site.
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Operating Instructions
3 302 715 en
08.02.2018
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MAXbase
Additional outrigger spans
In addition to the information in the supplied Operating manual there are lifting
capacity tables for further outrigger spans. These additional pages only show the
additional outrigger spans.
Outrigger span type Three / One
Three outrigger beams are extended the same distance and one outrigger beam
has a smaller outrigger span.
GMK5180-1 / GMK5200-1 / GMK5250L
– One outrigger span smaller – Left
FR FL RR RL
I 3.900 m 2.155 m 3.900 m 3.900 m
II 3.900 m 3.900 m 3.900 m 2.155 m
– One outrigger span smaller – Right
FR FL RR RL
III 2.155 m 3.900 m 3.900 m 3.900 m
IV 3.900 m 3.900 m 2.155 m 3.900 m
There are no separate lifting capacity tables
for this type. The lifting capacities for the
type One outrigger span smaller – left are ena-
bled in a correspondingly mirrored slewing
range; à Supplied operating manual.
24.08.2018
Additional pages MAXbase 3 302 801 en 1
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The operating instructions consist of the
following chapters
1 Overview
2 Basic safety instructions
3 Operating elements for driving
4 Starting the engine for driving / switching it off
5 Driving
6 Driving modes and rigging for on-road driving
7 Malfunctions in driving mode
8 Operating elements for crane operation
9 Starting/switching off the engine – for crane
operation
10 Crane operation
11 Rigging work
12 Driving with a rigged truck crane
13 Transportation
14 Malfunctions during crane operation
15 Index
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Operating Instructions GMK5200-1 3 302 715 en
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5
5 Driving
5.1 Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
5.1.1 CHECKLIST: Checks before on-road driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
5.1.2 Check the condition of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
5.1.3 Adjusting the seats and steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12
5.1.4 Switching the suspension on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
5.1.5 Setting the tachograph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
5.1.6 Setting the time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
5.1.7 Displaying and resetting operating hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23
5.2 Operating the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25
5.2.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25
5.2.2 Switching the transmission to the neutral position . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
5.2.3 Selecting the direction of travel and starting gear. . . . . . . . . . . . . . . . . . . . . . . . 5 - 27
5.2.4 Changing the operating mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 29
5.2.5 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 30
5.2.6 Driving and changing gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 31
5.2.7 Changing 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 and parking off the truck crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35
5.3.1 Checks while driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35
5.3.2 Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39
5.3.3 Temposet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 40
5.3.4 Driving downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 41
5.3.5 Driving uphill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 44
5.3.6 Override torque reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 45
5.3.7 Switching the truck crane off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 46
5.3.8 Folding berth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 48
5.4 Off-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 49
5.4.1 Longitudinal and transverse differential locks . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 50
5.4.2 Operating the level adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 52
5.4.3 Freeing an immobilized truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 56
5.5 Separate steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 59
5.5.1 Switching to separate steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 59
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Operating Instructions GMK5200-1 3 302 715 en
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10
10 Crane operation
10.1 Before operating the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
10.1.1 CHECKLIST: Checks before operating the crane . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
10.1.2 Check the condition of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
10.1.3 Adjusting the crane cab seat and front control panel . . . . . . . . . . . . . . . . . . . . 10 - 8
10.1.4 Checking the safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10
10.1.5 Earthing the load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 13
10.1.6 Preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 14
10.1.7 Locking/unlocking the superstructure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15
10.1.8 Switching the houselock on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17
10.2 Standard slewing range type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 21
10.2.1 Permissible slewing ranges and working positions . . . . . . . . . . . . . . . . . . . . . 10 - 21
10.3 MAXbase slewing range type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 23
10.3.1 Specifications in the lifting capacity tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 24
10.3.2 Enabled slewing ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 25
10.3.3 Lifting capacities and slewing ranges for outrigger spans
without separate lifting capacity tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 28
10.4 Operation of the rated capacity limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 29
10.4.1 Switch on the RCL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 30
10.4.2 Enter rigging mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 32
10.4.3 Pre-selecting telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 40
10.4.4 Confirm the rigging mode and lifting capacity table . . . . . . . . . . . . . . . . . . . . . 10 - 41
10.4.5 Checks before operating the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 45
10.4.6 Displays during crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 49
10.4.7 RCL early warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 57
10.4.8 RCL shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 58
10.4.9 Displaying the lifting capacity tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 59
10.4.10 RCL override – version A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 63
10.4.11 RCL override – version B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 67
10.4.12 Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 68
10.5 Crane operation with main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 73
10.5.1 Checks during crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 73
10.5.2 Main hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 75
10.5.3 Auxiliary hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 79
10.5.4 Lifting limit switch and lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 82
10.5.5 Derricking gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 85
10.5.6 Telescoping mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 89
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Operating Instructions GMK5200-1 3 302 715 en
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15
15 Index
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Operating Instructions GMK5200-1 3 302 715 en
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Overview
1.5 Technical data
Dimensions All dimensions relate to on-road mode; à Driving modes, p. 6 - 1.
Length without auxiliary 15.68 m
hoist:
A Height: At on-road level:
– 385/95 R25 3.94 m
– 445/95 R25 3.99 m
– 525/80 R25 3.99 m
Max. level change -130/+170 mm
B Width:
– 385/95 R25 2.97 m
– 445/95 R25 2.97 m3.07 m
– 525/80 R25
Angle of negotiable banks: At on-road level (385/95 R25)
front: approx. 16°
rear: approx. 8°
Weight and For equipment with the specified axle loads in on-road mode;
axle loads à Driving modes, p. 6 - 1.
Dimensions and weights of the parts which have to be transported on
separate vehicles when driving on the road; à
p. 1 - 10.
Total weight: depending on driving mode 60 t
Axle loads: depending on driving mode 12 t
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Operating Instructions GMK5200-1 3 302 715 en 1-9
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Overview
1.5 Technical data
1.5.5 Superstructure
Main hoist
Drum diameter: 458 mm (rope centre to rope centre)
Rope diameter: 22 mm
Rope length: 300 m
Rope pull: 104 kN/line
Power unit group: M 3 (to ISO 4301 - 2)
Load spectrum: L1
Factor of the load spectrum Km = 0.125
Theoretical service life: D = 3,200 h
Auxiliary hoist
Drum diameter: 458 mm (rope centre to rope centre)
Rope diameter: 22 mm
Rope length: 300 m
Rope pull: 104 kN/line
Power unit group: M 3 (to ISO 4301 - 2)
Load spectrum: L1
Factor of the load spectrum Km = 0.125
Theoretical service life: D = 3,200 h
Slewing gear
Make: Siebenhaar
Type: 01 DD
Power unit group M2 (to ISO 4301 - 2)
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Operating Instructions GMK5200-1 3 302 715 en 1 - 19
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Overview
1.7 Notes on the operating manual
1.7.3 How do I find the information I need?
The operating manual contains the following guides for orientation.
– The Contents lists all chapters in the operating instructions.
– The Table of contents provides an overview of the topics.
– The Index in chapter 15 gives an alphabetic list of keywords and search
terms with a reference to the relevant page in the operating manual.
à
– Cross-references are labelled with an arrow ( ) 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 to specific information on the truck crane or look
up the functioning of individual elements.
The following pages give an example of how to use the cross-references.
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Operating Instructions GMK5200-1 3 302 715 en 1 - 29
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Basic safety instructions
2.1 Intended use
2 Basic safety instructions
à What do the symbols used mean?, p. 1 - 25.
H
Notes on the warnings used;
2.1 Intended use
The GMK5200-1 truck crane is constructed in accordance with the latest
technology and the recognised safety regulations. Nevertheless, the opera-
tor or third parties can still be endangered and the crane or other property
put at risk while using it.
The truck crane may only be modified with the consent of Manitowoc Crane
Group Germany GmbH.
The GMK5200-1 truck crane may be used only when it is in perfect technical
condition and for its intended purpose and with due attention paid to safe
operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately.
The GMK5200-1 truck crane may only be operated without the correspond-
ing special equipment within the permitted temperaturerange; à
Technical
data, p. 1 - 7.
The GMK5200-1 truck crane is designed solely for lifting loads which are
within the permitted GMK5200-1 lifting capacities. The load must be slung
as prescribed to a hook block which is positioned vertically over the load
prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating
manual(s), the lifting capacity table, the outrigger pressure table and the
safety manual
– adhering to the inspection and maintenance requirements specified in the
maintenance manual.
The GMK5200-1 may only be operated with parts of equipment which have
been approved by Manitowoc Crane Group Germany GmbH and which are
labelled with the serial number of the GMK5200-1.
The manufacturer is not liable for any damage caused by improper or unau-
thorized use of the GMK5200-1 truck crane. The user shall take on full
responsibility for any such use.
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Operating Instructions GMK5200-1 3 302 715 en 2-1
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Basic safety instructions
2.6 Instructions on transporting persons
The crane operator must have knowledge of and meet the requirements of
the relevant legal regulations and standards (e.g. the BGR 159 in Germany
or the ASME B30 in the USA).
The crane operator must have the necessary knowledge for operating the
truck crane and the equipment used for lifting persons.
The crane operator and the persons to be transported must be made aware
of all the known dangers involved when transporting persons.
Operation Operations planning for transporting persons must be carried out with spe-
cial care. If official registration is required in the country in which you are
working, this must be done with the relevant authorities in good time.
The truck crane must be rigged as prescribed and be level.
Before transporting persons, the crane operator must make sure that the
safety devices and emergency operation functions are in perfect working
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 stored in the crane
cab and within 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 persons has been set down and the person transported has left it.
The crane operator must take care that the degree of utilisation does not
exceed 50% during operation.
The number of reeved rope lines must be selected such that the load on the
hoist rope does not exceed 50% of the rope pull. At the same time, the total
weight of the lifted load must be considered, consisting of the weights of the
hook block, the lifting gear and the equipment for lifting persons including
the maximum payload.
When transporting persons, the crane operator must maintain the safe dis-
tances from overhead power lines applicable in the country in which he is
working. The distances are normally greater than the distances for lifting
loads specified in the section Safe distance from overhead power lines.
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Operating Instructions GMK5200-1 3 302 715 en 2 - 11
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Operating elements for driving
3.1 Overview of the operating elements
20 Radio1), 2)
21 BirdView-System 270°– monitor1) à p. 3 - 57
22 Heating/Air-conditioning system 1)
à p. 3 - 20
23 CCS control unit à p. 3 - 24
Reverse camera monitor à p. 3 - 56
24 Loudspeakers
25 Sockets 12 V/24 V à p. 3 - 50
Cigarette lighter
Ashtray
26 Behind the cover à p. 3 - 10
27 Fastening for the folding berth 1)
à p. 5 - 48
28 Cab lighting à p. 3 - 71
29 Battery heater2)
30 Auxiliary air heater1) à p. 3 - 23
1)
Additional equipment
2)
à Separate operating instructions
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Operating Instructions GMK5200-1 3 302 715 en 3-9
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Operating elements for driving
3.1 Overview of the operating elements
3.1.7 Tachograph
r
(A) – Tachograph1)
1 Display à p. 5 - 20
2 Time correction –: à p. 3 - 74
3 Time correction +: à p. 3 - 74
4 Opening the drawer à p. 5 - 18
5 Setting the time group – driver 1 à p. 5 - 19
6 Setting the time group – driver 2 à p. 5 - 19
7 Tachograph à p. 3 - 74
8 Drawer à p. 5 - 18
(B) – Cover1)
9 Time correction –: à p. 3 - 74
10 Time correction +: à p. 3 - 74
1)
(A) or (B) present, depending on the version
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Operating Instructions GMK5200-1 3 302 715 en 3 - 19
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Operating elements for driving
3.1 Overview of the operating elements
1 Carrier menu group à p. 3 - 30
– Suspension/ level adjustment menu
– Driving menu
2 Settings menu group à p. 3 - 33
– Set display brightness and date/time menu
3 Information menu group à p. 3 - 35
– Operating hours menu
– Engine/transmission error menu
– Crane operation error menu
4 Various controls menu group à p. 3 - 39
– Spotlights on rear of carrier on/off
– Reverse camera on/off1)
5 Emergency operations menu group à p. 3 - 39
– Hydraulic emergency operation on/off
– Towing mode on/off
1)
Additional equipment
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Operating Instructions GMK5200-1 3 302 715 en 3 - 29
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Operating elements for driving
3.1 Overview of the operating elements
3.1.16 Various controls menu group
1 Spotlights on rear of carrier on/off à p. 3 - 70
2 Reverse camera on/off à p. 3 - 56
3.1.17 Emergency operations menu group
à p. 14 - 54
08.02.2018
1 Hydraulic emergency operation on/off
2 Towing mode on/off à p. 7 - 27
Operating Instructions GMK5200-1 3 302 715 en 3 - 39
--- Page 17 ---
Operating elements for driving
3.2 Brief description of the operating elements
CCS display
Adblue filling level monitoring submenu
– Display Green: Over 10% – over 4 l
Yellow: 5 to 10% – 2 to 4 l
Red: Below 5% – less than 2 l
3.2.5 Battery master switch
– Switch on: Push up