PDF Operating Manual Manitowoc Grove GMK5150L Crane - 5 MB
This is the official operating manual for the powerful Manitowoc Grove GMK5150L crane.
It contains critical information regarding safe operation, load capacity charts, and control systems.
Operators will find detailed procedures for setup, rigging, and execution of lifts.
Adherence to this manual is mandatory for ensuring job site safety and maximizing the crane's impressive capabilities.
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Operating manual
3 302 709 en
12.01.2018
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2
2 Basic safety instructions
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
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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
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12
12 Rigging work
12.1 Rigging work checklists for crane operation with the main boom . . . . . . . . . . 12 - 1
12.1.1 CHECKLIST: Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1
12.1.2 CHECKLIST: Unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 7
12.2 Choice of a suitable positioning site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11
12.2.1 Determining the required load-bearing area . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11
12.2.2 Safe distance from slopes and pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14
12.2.3 Earthing the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 15
12.2.4 Safe distance from overhead power lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 16
12.3 Rigging work after driving with a dolly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19
12.3.1 Switching off the boom floating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19
12.3.2 Switching off the slewing gear freewheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20
12.3.3 Switching off boom pre-tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 21
12.4 Connecting/disconnecting the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . 12 - 23
12.5 Starting the engine for rigging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 27
12.5.1 Starting/shutoff the engine – with the hand-held control . . . . . . . . . . . . . . . . . 12 - 27
12.5.2 Starting/shutoff the engine – from the outrigger control 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 CHECKLIST: Extending the outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 41
12.8.2 CHECKLIST: Retracting the outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 43
12.8.3 Preparing the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 44
12.8.4 Setting the outrigger spans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 46
12.8.5 Extending/retracting outrigger beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 49
12.8.6 Moving the outrigger pads into operating/driving position . . . . . . . . . . . . . . . 12 - 53
12.8.7 Enlarging the load-bearing area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 55
12.8.8 Extending/retracting supporting cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 56
12.8.9 Levelling the truck crane on outriggers horizontally . . . . . . . . . . . . . . . . . . . . . 12 - 60
12.8.10 Levelling the free-standing truck crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 64
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12.8.11 Operating the axle raising system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 66
12.8.12 Outrigger pressure display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 68
12.9 Rigging/unrigging the counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 71
12.9.1 Information on rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 71
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Overview
1.2 Branch offices
1.2 Branch offices
1.2.1 Manitowoc Crane Care
If you need help or support with the operation on your truck crane, you can
contact our branches at the following addresses Manitowoc Crane Care:
http://www.manitowoccranes.com
1.2.2 Dealer list
Visit the following address for a global list of dealers:
http://www.manitowoccranes.com
1.3 Warranty specifications
Please see the separately enclosed warranty certificate for information.
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Overview
1.5 Technical data
Versions with ballast plate – Version A
(1) x (2) x (3) Weight
Description
in m In kg
Hook block 1.41 x 0.56 x 0.44 450
1 sheave with ballast plates (4.63 x 1.84 x 1.44)
Hook block 1.41 x 0.56 x 0.35 325
1 sheave without ballast (4.63 x 1.84 x 1.15)
plates
1 ballast plate 19
Hook block 1.47 x 0.56 x 0.51 950
3 sheave with ballast plates (4.82 x 1.84 x 1.67)
Hook block 1.36 x 0.53 x 0.30 440
3 sheave without ballast (4.46 x 1.74 x 0.98
plates
1 ballast plate 25
Auxiliary hoist
Length x width x height Weight
Description
in m (ft) in kg (lbs)
Complete auxiliary hoist 0.80 x 1.70 x 0.70 1,200
(2.62 x 5.58 x 2.29) (2,646)
s
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Overview
1.6 Documentation supplied
1.6 Documentation supplied
The precise number of documents supplied depends on the rigging mode
of the truck crane. The following documents are included in delivery:
– Operating manual
Contains information on driving and crane operation.
– Lattice extension operating manual
Is only supplied when the truck crane is equipped with a lattice extension
or other parts for extending the main boom (for example, auxiliary single-
sheave boom top and heavy load lattice extension).
– Operating manual for additional equipment
This is only supplied when 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 equipment.
– Maintenance manual
Contains solely information on maintenance work and contains no
instructions for repair work.
– Safety manual
Provides information on the safe operation of the truck crane.
– Circuit diagrams
Circuit diagrams for the electrical systems, hydraulic systems and pneu-
matic systems are supplied.
– Lifting capacity table
Information on the lifting capacity when the truck crane is in different
rigging modes.
s
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GMK5150L
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Overview
1.8 Conversion table for US measuring units
1.8 Conversion table for US measuring units
The following conversion factors will help you convert from metric to
US units and vice versa when the truck crane is being used in countries
that use US units of measurement.
Converting from into Multiply by
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/h or km 1,60935
Nm lbf ft 0,7375
°C °F 1.8 x °C+32
°F °C (°F-32)/1.8
t/m2 lbs/ft2 204,8
m2/t ft2/lbs 0,04882
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GMK5150L
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Basic safety instructions
2.3 Personnel qualifications
Appropriate servicing equipment is absolutely necessary in order to carry
out maintenance work.
Observe national regulations that apply to transport when loading the truck
crane. Also observe the additional safety measures prescribed by the for-
warder (e.g. shipping or railway transportation company).
Monitor the work of personnel, at least occasionally, and make sure they
work in accordance with the operating instructions in a safe and conscien-
tious manner.
2.3 Personnel qualifications
This operating manual is not a training manual for prospective crane
operators!
All descriptions are written explicitly for crane operators who have been
trained to operate truck cranes.
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 have general knowledge about working with cranes and the
qualifications required in the country in which you are working.
– You must be familiar with and understand the operating instructions.
– You must be familiar with and have understood the accident prevention
regulations.
– You must fulfil all physical and mental requirements for truck crane
operation, e.g. perfect sight and hearing and the ability to react quickly.
Please also refer to the section in the Safety manual titled You as driver and
crane operator.
s
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Operating elements for driving
3.1 Overview of the operating elements
1 Front flap à p. 3 - 73
2 Driver's cab à p. 3 - 6
3 Hose drum, installing/removing1), 2)
4 Engine for driving à p. 4 - 1
5 Rigging the main boom1), à p. 6 - 17
6 Auxiliary hoist Operation1) à p. 9 - 116
Rigging the auxiliary hoist1) à p. 6 - 39
7 APS connection/interface
(Auxiliary Power Supply) 1), 3)
8 – Spare wheel1) à p. 8 - 33
– Towbar coupling1) à p. 5 - 81
– Third brake light – At the rear of carrier/storage à p. 5 - 12
compartment1)
– Third brake light – At the spare wheel clamp1) à p. 8 - 35
9 BirdView system 270° – Camera 1)
à p. 3 - 53
10 Chocks1) à p. 5 - 46
11 Storage space for the folding ladder à p. 3 - 77
12 Outriggers
– Operation à p. 12 - 41
– Lighting à p. 12 - 45
– Installing/removing the outrigger beams à p. 6 - 51
13 Swing-out ladders à p. 3 - 77
14 – Fuel tank à p. 4 - 5
– Dual tank1) à p. 4 - 6
15 – Outrigger control units à p. 3 - 38
– Emergency stop switch à p. 4 - 19
16 Step at the crane cab Switching on/off à p. 12 - 157
1)
Additional equipment
2)
à Lattice extension operating manual
3)
à Separate operating manual
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Operating elements for driving
3.1 Overview of the operating elements
1 Indicator lamp for turn signal indicator à p. 3 - 66
2 Indicator lamp for trailer turn signal indicator1) à p. 3 - 66
3 Speedometer à p. 3 - 70
4 On-board computer à p. 3 - 15
5 Tachometer à p. 3 - 43
6 Power steering malfunction à p. 8 - 6
7 Malfunctions on the engine à p. 8 - 19
8 Engine speed too high warning à p. 3 - 43
9 Brake malfunction à p. 3 - 58
10 ABS warning à p. 5 - 35
11 Display:
– Time à p. 3 - 73
– Outdoor air temperature 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 Steering malfunction à p. 3 - 60
21 Steering circuit 1 warning à p. 3 - 60
22 Steering circuit 2 warning à p. 3 - 60
23 Steering circuit 3 warning à p. 3 - 60
24 AdBlue (DEF) level indicator à p. 4 - 7
1)
Additional equipment
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GMK5150L
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Operating elements for driving
3.1 Overview of the operating elements
3.1.11 CCS – Start menu
1 Display of crane type
2 Serial number display
3 Display of transverse and longitudinal differential à p. 3 - 28
locks on/off
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
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Operating elements for driving
3.1 Overview of the operating elements
Operating
hours menu
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
s
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Operating elements for driving
3.2 Short description of the operating elements
Setting cruise control
The truck crane must be driving at a speed at
least 15 km/h (9 mph).
2 Select the Cruise control menu –
symbol (1) is grey
3 Switches on or increases the speed –
symbol (1) is white
4 Switches on or reduces the speed
5 switch off
à p. 5 - 38
Setting the Temposet
The truck crane must be driving at a speed at
least 15 km/h (9 mph).
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 Temposet off
à p. 5 - 40
Instrument panel
Tachometer
Display, engine speed in rpm; à p. 5 - 37
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Operating elements for driving
3.2 Short description of the operating elements
3.2.10 BirdView system 270°
The BirdView system 270° is a driving assistance system.
The BirdView system 270° does not relieve you of the responsibility for
maintaining a sufficient safe distance or braking in time! Drive with due care
and attention! The sole responsibility 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.
S
Risk of damage in driving mode
Obstacles in the driving area above the height of the camera are not
displayed. Always also watch the driving area using the mirrors. This will
avoid damage to the truck crane.
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
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Operating elements for driving
3.2 Short description of the operating elements
Separate steering crab travel mode on/off
– Switch on: Select symbol (1) and confirm – Symbol (2) is displayed
– Switch off: Select a different steering mode – Symbol (3)
à p. 5 - 60
Manual separate steering on/off
– Switch on: Select symbol (1) and confirm – Symbol (2) is displayed
– Switch off: Select a different steering mode – Symbol (3)
à p. 5 - 60
When separate steering is switched on, the speed is limited.
Current wheel position display
The current status is shown using different
symbols:
1 Straight ahead
2 Driving around corners
3 Crab travel mode
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GMK5150L
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Operating elements for driving
3.2 Short description of the operating elements
Tour data menu
1 Total mileage
2 Daily mileage
3 Time
4 Outside temperature
3.2.22 Front flap
Opening