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1. GMK 5100 Gear Control System
1.1 GMK 5100 gearbox (transmission)

1.2 Overview of transmission

2. Gear and clutch selection

2.1 Gear and clutch selection with Telligent automatic gear change

2.2 Components of the Telligent automatic gear change

2.3 Operating conditions

2.3.1 Road drive (constant speed)

2.3.2 Starting
2.3.3 Gear shift

3. Gear selector

3.1 Gear selector

3.2 Starting

3.3 Selecting operating mode - Automatic operation

3.4 Manual operation

3.5 Gear selection by the electronics

3.6 Gear selection by driver

3.7 Emergency shift on transmission with Telligent shifting

3.8 Perform emergency shift

3.8.1 Emergency shift with emergency switch
3.8.2 Emergency shift when the vehicle is stationary

4. Programming Procedure

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1. GMK 5100 Gear Control System

1.1 The GMK 5100 is equipped with a pneumo-electronically operated 16-speed G240-16
gearbox. Gears can be preselected manually or automatically. During emergency
service, gears are selected pneumatically.
1.2 Overview of gears selection mechanical: Fig 1
Fig. 2
Fig. 3

Fig. 1

5
4
5
3 2

1 Central plug X 29
2 Solenoid GV Y29/Y30
3 Gate solenoid valve Y33/34
4 Sensor split B62
5 Sensor Range B63
6 Solenoid GP Y31/32
7 Sensor Gate B61

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Fig. 2

4
2 3

1 Gear sensor B 60
2 Gear solenoids Y35/Y36
3 Gear solenoids Y37/Y38
4 Countershaft speed sensor B 3
5 Sensor Clutch B2

Fig. 3

1 Output speed sensor B 57

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2. Gear and clutch

2.1 Gear and clutch with Telligent automatic gear change

The Telligent automatic gear change is a system, which allows the crane to be started and its
gears changed with the engine, dry clutch and gearbox without having to activate a clutch
pedal. The gears can either be shifted manually by the driver via a transmitter or automatically
by the electronic control system.

2.2 Components of the Telligent automatic gear change

• Telligent gear shift

• Telligent engine system comprising:
• drive control system FR (FMR) and
• engine control system MR (PLD) including unit pump cylinders
• clutch control system comprising
• clutch control KS(MKR) and
• clutch operation KB(EMK), which disengages the clutch
• automatic gear selection AG(AGE).

The electronics FMR, GS(EPS), KS and AG communicate equally via a high-speed bus (high-
speed CAN); FMR and PLD as well as KS and KB are connected to one another via separate
bus systems (low-speed CAN).

When emergency service is activated, the electrical operation of the clutch is switched off and
is activated directly via a clutch pedal via a safety valve.

2.3 Operating conditions

The KS electronics control the logical linking of the three components engine, clutch and
transmission depending on the travelling condition, with due regard to the input variables and
signals (from the transmitter, position of the accelerator, speeds, etc.). Fig. 1

2.3.1 Road drive (constant speed)

In this travel condition, during the on-road driving, the nominal value for the engine torque is
determined directly by the accelerator via the FMR, the clutch is closed.

2.3.2 Starting

The clutch is engaged in a controlled manner according to the torque setting of the
accelerator, during which time the engine is kept at idling speed. Please see fig. 2 for details
about the control operation.

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2.3.3 Gear shift

After a gear request from the driver (with gear shift selector) or the system (automatic gear
selection), the combination – engine and clutch – is just controlled in time by the transmission
electronics. The output speed is automatically adjusted to the transmission input rate via the
output speed control, fig. 3.

The automatic gear selection determines the respective gear depending on the travel
condition, output speed, etc. The lowest possible fuel consumption is thereby striven for at
constant speed. Overspeeds and excessively low speeds as well as pendulum shifts are
avoided. Fig. 4 shows the basic course of this process.

If the “brakes” pilot lamp illuminates, the driver must activate the brake pedal, giving the
electronics a chance to change down.

The clutch subsystem

Fig. 1 Protection/Emergency system

Actuator

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Fig. 2 Low gear

Fig. 3 Gear shift

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Fig. 4

Automatic gear selection

Acquisition of
measuring data
(via CAN)

Accelerator Vehicle
Speed
Output speed
condition
FR Engine torque Shift
routines
Vehicle
weight Traction
Actual gear upshift Shift
Gradient
Input
of road
philosophy
GS speed
Clutch path Changing Delay in nominal
down gear Shifting

Nominal
gear

ABS signal Driver’s Thrust upshift Fade out of

BS ASR signal wish nominal gear
Speed VA
Thrust
downshift

Position of the
RS retarder lever

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3. Gear selector
3.1 Gear selector

2 5

3
6

1
8
4
7

1 Control key

2 Change down gear / reverse gear

3 Upshift gear / forward gear

4 Neutral key

5 Change down/Reverse gear

6 Upshift / forward gear

7 Splitter

8 Automatic/Manual operation switch

3.2 Starting

To start, only 1st to 4th gears can be selected from Neutral (N).
Low gears =
-1st gear = Press control key and move gearshift lever forwards.
-2nd gear = Move gearshift lever forwards.
-3rd gear = Move gearshift lever forwards and release. Press control key and
move gearshift lever forwards a second time.
-4th gear = Move gearshift lever forwards. Release gearshift lever and
move it forwards a second time

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Preselecting low gear:

- Activate gearshift lever, control key and splitter and release. The low gear selected will
flash on the display. If a low gear is preselected from Neutral (N) when the vehicle is
stationary or the service brake or parking brake is activated, the preselection will be stored
for 2 minutes (for 10 seconds if the service/parking brake is released). If the
service/parking brake is activated during the time the preselection is stored, the storage
time will be extended to 2 minutes.
- Disengage clutch, the gear is shifted to the selected low gear and this is shown on the
display. Reverse and Neutral cannot be preselected.

Changing low gear:

- If a low gear is to be changed, activate the Splitter (or control key and gearshift lever)
again from the mid-position (normal position).

Cancel preselection of low gear:

- Activate neutral key

Selecting operating mode

The driver can choose between two operating modes (automatic/manual).

3.3 Automatic operation

In automatic operation, the optimum gear at any one time is determined and selected
according to the travelling condition, the position of the accelerator and the operating
condition of the engine, etc. The Telligent automatic gear change automatically controls the
clutch operation and gear shift.
When the vehicle is stationary and the service brake or parking brake is activated:
- Press and hold the control key on the gearshift lever and move the gearshift lever forwards
or backwards (reverse).
1st - 4th gears can be selected.
- Release brakes and activate accelerator. The vehicle starts.

Upshift
- Replace with Light acceleration: Upshift at low output speed.
- Replace with heavy acceleration: Upshift at high output speed.

Changing down
Gear shifts in the low gears depend on the position of the accelerator.

Stopping

When the vehicle is stopping, the clutch is automatically disengaged shortly before the idle
speed is reached. When the vehicle is stationary, a suitable low gear is automatically selected.

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3.4 Manual operation

In manual operation the driver can choose whether to have gears selected by the electronics or
whether to select them himself. The Telligent automatic gear change automatically controls
the clutch operation and the gear shift.

When starting, only the 1st to 4th gears can be selected from Neutral (N).
If the vehicle is stationary and the service brake or parking brake is selected
- Press and hold control key on the gearshift lever and move gearshift lever forwards or
backwards (reverse). The gear is automatically shifted to the 2nd gear of the fast speed
group (every gear has a low speed and a fast speed group).
Changing low gear:
The low gear can be changed by activating the control key and gearshift lever, the
gearshift lever or the Splitter.
- Release brakes and activate accelerator. The vehicle starts.

Gear shift

3.5 Gear selection by the electronics (EPS selection)

The driver determines the shift direction by activating the gearshift lever. The electronics
determine the suitable gear level (nominal gear) for the shift direction selected. The nominal
gear depends on the operating conditions (travelling speed, vehicle loading, position of
accelerator, etc.)

Shift direction:
- Shift direction forwards = upshift
- Shift direction backwards = changing down
If a warning buzzer sounds, no downshift will be made. The permissible output speed has
been exceeded.
The gear can only be shifted in the selected shift direction.

Shift
- Operate gearshift lever. The shift is completed when the selected gear level is indicated on
the display.

3.6 Gear selection by driver

The driver determines the shift direction and the gear level by activating the gearshift lever
and control key or the Splitter.

Shift direction and speed level

Upshift:
By ½ gear = Move Splitter upwards.

- By 1 gear = Press and hold control key and move gearshift lever backwards.If the
warning buzzer sounds, no downshift or only a limited downshift will be made. The
permissible output speed has been exceeded.

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Neutral (N)

The gear can only be shifted to Neutral if the gearshift lever and Splitter are in the mid-
position (normal position).

- Confirm neutral button.

The shift is completed when “N” appears on the display.

Stopping

When the vehicle is stopping, the clutch is automatically disengaged shortly before the idle
speed is reached. The vehicle stays in the same gear, in which it is stopped.

Note

- If the vehicle is stopped when it is in 5th to 8th gear, it cannot start again in this gear. Select
a suitable low gear from 1st to 4th gear to start.

- If the vehicle stands for more than 90 seconds with the engine running, the gear is
automatically shifted to Neutral (N). After 60 seconds “Neutral” flashes on the display. If
the accelerator is touched briefly, the vehicle remains in the selected low gear for a further
90 seconds.

3.7 Emergency shift on transmission with Telligent shifting

Release emergency clutch pedal.

Pull release lever for
emergency clutch pedal.

Emergency clutch pedal (retracted)

???eingeklappt)

Release lever for

emergency clutch pedal

Emergency clutch pedal

(extended)

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3.8 Perform emergency shifts:

1
G
2
R
NL

NH

1 = Tilt lid upwards

G = Normal position (Neutral)
2 = 2nd gear
NL = Neutral (slow upshift group)
NH = Neutral (fast upshift group)
5. = 5th gear
R = Reverse

3.8.1 Emergency shift with emergency switch

Swing up cover of the emergency switch. The emergency switch is in the normal position and
is not operative:
- During travelling.
- If the key in the steering wheel lock is in the travelling position and no fault (emergency
clutch prompt symbol) is shown.
Note!

- If the display indicates a fault (prompt for emergency clutch), stop vehicle and perform
emergency shift.

3.8.2 Emergency shift when the vehicle is stationary:

- Press clutch pedal right down and hold.

- Start engine.

- Shift gear

Neutral:
If a gear is selected, push emergency switch down from “G” position and hold for approx. 1
second. Release emergency switch.

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2nd gear:

Push emergency switch down from “G” position, turn clockwise to the 2 nd gear marker and
hold for approx. 1 second. Release emergency switch.

5th gear:

Push emergency switch down from the “2nd gear” position, turn clockwise to the “NL” marker
and hold for approx. 2 seconds. Release emergency switch.
Push emergency switch down from the “NL” position, turn clockwise to the “NH” marker and
hold for approx. 2 seconds. Release emergency switch.
Push emergency switch down from the “NH” position, turn clockwise to the “5th gear” marker
and hold for approx. 1 second. Release emergency switch.

Reverse:

Push emergency switch down from the “G” position, turn clockwise to the „r. gear“ marker
and hold for approx. 1 second. Release emergency switch.

- Slowly release clutch pedal.

Gear shift
Shifting from 2 nd to 5th gear (while travelling on a level road):

- Press clutch pedal right down and hold.

Push emergency switch down from the “2nd gear” position, turn clockwise to the “NL” marker
and hold for approx. 2 seconds. Release emergency switch.
Push emergency switch down from the “NL” position, turn clockwise to the “NH” marker and
hold for approx. 2 seconds. Release emergency switch.
Push emergency switch down from the “NH” position, turn clockwise to the “5th gear” marker
and hold for approx. 1 second. Release emergency switch.

- Slowly release clutch pedal.

Shifting from 5th to 2nd gear:

Only when the vehicle is stationary with the engine running (idling speed)

- Press clutch pedal right down and hold.

Push emergency switch down from the “5th gear” position, turn clockwise to the “NH” marker
and hold for approx. 2 seconds. Release emergency switch.
Push emergency switch down from the “NL” position, turn clockwise to the “NH” marker and
hold for approx. 2 seconds. Release emergency switch.
Push emergency switch down from the “NL” position, turn clockwise to the “2nd gear” marker
and hold for approx. 1 second. Release emergency switch.

- Slowly release clutch pedal.

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4. GMK 5100
Transmission
Programming Procedure
The programming is necessary, if the following items are exchanged:
Direction sensors, master cylinder, slave cylinder, protection valve, KB (EMK), electronic KS
(MKR)

• Ignition off
• Press both buttons (function and neutral button) with left hand
• Switch on ignition with right hand
• If „N“ flashes, start engine, 02K21 is to be operated by hand
• If „N“ lights up again, the programming procedure is finished.

During the entire programming procedure, the buttons are to be pressed !!

If the programming procedure cannot be carried out, the emergency pedal

is to be turned out.

• Ignition off
• Press emergency pedal
• Press both buttons (function and neutral button) with left hand
• Switch on ignition with right hand
• If „N“ flashes, start engine, 02K21 is to be operated by hand
• If buzzer sounds, release emergency pedal
• If buzzer sounds, press emergency pedal
• Repeat this press and release procedure until “N” lights up again
• Now the programming procedure is finished.

Programming of electronic KS with Minidiag 2

• Connect Minidiag 2
• Select electronic KS and call “Routine“
• Follow the on-screen instructions

Attention: The vehicle moves !

For that reason, at least 5m space is necessary in
front of the vehicle!

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