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Copyright reserved by leerleerleerleerleer leer
16.02.2000
The passing on or duplication of this document as well as the utilization and disclosure of its contents are prohibited
unless expressly permitted. Infringement will incur liability to compensation. All rights pertaining to registration of patent
or utility model are reserved.
The following chapters are contained in these operating
instructions:
1 Important information
4 Boom extension
Alphabetical index
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2.2 In US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
2.2.1 Two-stage swing-away lattice extension and boom extension . . . . . . . 2-2
2.2.2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
3.6 Raising and setting down the main boom with rigged lattice extension . . . 3 - 63
4.5 Driving with rigged crane and lattice extension or boom extension installed 4 - 19
4.5.1 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
4.5.2 Position of the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
4.5.3 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
5.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
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1 Important information
H
1.1 About these operating instructions
Validity of this This operating manual only applies to lattice extensions which were deli-
operating manual vered by Deutsche GROVE GmbH.
In addition, for the operation of the truck crane with a lattice extension
described in these operating instructions, all details in the included Opera-
ting Instructions for the GMK 5100 (for which the lattice extension was deli-
vered from the factory) are applicable.
Prerequisites for The lattice extensions described in these operating instructions may only
assembly and be operated together with a GROVE GMK 5100 truck crane whose serial
operation number is identical with the serial number that is marked on the lattice ex-
tensions.
Safety The operation of the GMK 5100 with one of the lattice extensions descri-
instructions bed in these operating instructions is subject to
s
Operating instructions for lattice extension 2 084 545 en 1-1
GMK 5100
Important information
1.2 Basic safety instructions
The following definitions and symbols are used in the operating instructi-
ons to highlight particularly important information:
G
This symbol indicates hazards related to the described operation that
may cause personal injury. The type of danger (e.g. danger of life, perso-
nal injury or risk of crushing) is as a rule specified in the warning sign.
S
Here dangers are referred to which could put objects at risk, e.g. damage
to the truck crane, the load or the environment.
B
This symbol alerts you to situations where you are in danger of receiving
an electric shock.
O
This symbol is to remind you that you are working with substances which
pose a risk to the environment. Take particular care. Further information
about handling substances which are harmful to the environment;
➠ Maintenance manual, Chapter Safety and environmental protection.
The vertical line to the left of the text indicates: this text regardless of its
length belongs to the warning symbol.
H The hand with the pointing finger indicates passages that contain additio-
nal instructions and tips with regard to truck crane operation.
s This symbol indicates that the topic is continued on the next page. So
turn to the next page!
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The truck crane may only be modified with the consent of the manufacturer.
The GMK 5100 truck crane must be in proper working condition and may
only be used for its intended purpose, while taking into account safe ope-
ration and any possible hazards.
Malfunctions that may affect the safe operation of the unit are to be
corrected immediately.
The GMK 5100 truck crane may only be operated at temperatures of bet-
ween – 25 and +40 °C if it is not equipped with the relevant special equip-
ment.
The GMK 5100 truck crane is to be used exclusivly for vertical lifting of
loads whose weight and centre of distribution are known. A hook block
must be reeved on the hoist rope and such lifting must be done only in
the permitted rigging modes. Any other use of the crane is considered im-
proper. The manufacturer is not liable for damage resulting from impro-
per or unauthorized use of the GMK 5100 truck crane. The user shall take
on full responsibility for any such use.
s
Operating instructions for lattice extension 2 084 545 en 1-3
GMK 5100
Important information
1.3 Proper use
Only properly trained or instructed personnel may carry out work on the
truck crane.
Responsibilities related to crane operation, rigging, maintenance and re-
pair work must be clearly defined.
Ensure that only the appointed employees operate the truck crane.
Do not leave long hair down or wear loose clothing or jewellery (including
rings) when working with the crane. These could get caught or pulled into
the unit and result in injury.
Ensure that all safety and warning signs on the truck crane remain legible.
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s
Operating instructions for lattice extension 2 084 545 en 1-5
GMK 5100
Important information
1.4 Organizational measures
Note the operational organization on the site. Report your arrival to site
management. Ask for the personnel authorized to issue instructions.
Familiarize yourself with the location and operation of the fire extinguis-
hers on every site.
Note the fire alarm and fire fighting facilities on the site.
Should the operating behaviour of the truck crane change in such a man-
ner that safety is affected or if you doubt the truck craneïs operating safe-
ty, stop the machine immediately and inform the appropriate responsible
persons.
Do not modify or mount attachments to the truck crane without the con-
sent of the manufacturer, if such changes could affect the safety of the
unit. This also applies to
– installing safety devices,
– setting safety devices and valves.
Welding work on load-bearing parts may only be conducted by properly
qualified personnel following authorisation by the manufacturer. To avoid
any damage, especially to electronic parts, there are certain steps you
must take before doing any welding work. So always consult GROVE Pro-
duct Support before doing any welding work.
Ensure that both the prescribed periods and the periods specified in the
operating and maintenance instructions for regular testing, inspection
and maintenance work are maintained.
Replace the hydraulic hose lines at the prescribed intervals or have them
replaced, even if no safety defects are noticeable.
Employees in training may only operate the truck crane under strict super-
vision.
The Deutsche GROVE GmbH gives general and type-related crane opera-
tor and technical courses.
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Walk around the truck crane before beginning crane work. Check the con-
dition of the truck crane carefully using the check lists in the operating in-
structions. Do not assume that everything is in working order simply
because it was in working order when work was last completed.
Each day, before you start to work with the crane, check that all covers
and safety devices are correctly fitted and that they are all in a proper
working condition.
Check the safety devices each day before beginning work (SLI, lifting limit
switch, dead man’s switch, emergency stop switch for crane control).
Use the appropriate access aids when carrying out overhead rigging or
maintenance work. Do not use parts of the crane as access aids.
Walk only on those machine parts which are equipped with appropriate
steps and railings and therefore guarantee safety. During rigging and
maintenance work on machine sections above body height which have no
apparatus for walking, use the extendable ladder which accompanies the
machine (e. g. when reeving the hoist cable on the boom nose).
Keep all handles, steps, step treads and ladders free of dirt, snow and ice.
Check all operating and control elements in the crane operator’s cab
before starting the crane engine.
Monitor all warning and indicator lamps as well as the control instru-
ments when the engine is started!
When lifting a load, raise the boom to balance out the increase in radius
caused by the boom bending so that the load is lifted up when in a verti-
cal position and does not drag, injure helpers or fall into the hoist cable
diagonally (e.g. from a vehicle or scaffold). Inform banksmen and helpers
about this as well.
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Support the truck crane with the supporting span for the current rigged
counterweight before turning the superstructure.
Ensure that the truck crane is horizontally aligned before carrying out
crane work.
When work is interrupted, always put the load down and never leave the
truck crane if a load is raised.
Lock the truck crane when you leave the cab to prevent unauthorised use.
Crane work carried out in the vicinity of electric cables as well as oil, gas
and other supply lines is dangerous and requires that special precau-
tionary measures be taken. Please refer to the section titled Crane operation
under special operating conditions in the Safety Manual and observe the rele-
vant national regulations.
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– the first column shows the units of measurement as used in these in-
structions;
– the second column shows the converted units of measurement, which
are also used in the lifting capacity tables;
– the third column shows the rounded values which are used for better
legibility if both units of measurement are stated (in Chapter 2, Trans-
port dimensions and weights and in the diagrams showing the compo-
sition of the individual lattice extensions.
11 m 36.1 ft 36 ft
Lattice extension
18 m 59.1 ft 59 ft
Two-stage swing-away lattice
extension
26 m 85.3 ft 85 ft
Boom extension
34 m 111.6 ft 112 ft
Boom extension
7 m section 23.0 ft 23 ft
8 m section 26.2 ft 26 ft
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2.2 In US units
This section contains the transport dimensions and weights of the lattice
extensions in US units.
S
Only operate two-stage swing-away lattice extension sections which have
the same serial number as the crane.
The SLI is only set for this two-stage swing-away lattice extension.
H
This prevents malfunctions and damage.
For technical reasons a truck crane may only be set with one two-stage
swing-away lattice extension.
S
The two-stage swing-away lattice extension should only be adjusted by
your local GROVE Product Support!
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s
Operating instructions for lattice extension 2 084 545 en 3-1
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.1 Identification of the two-stage swing-away lattice extension
Serial numbers The 11 m section consists of a fixed section and an inclinable section.
on 11 m section
On the inclinable section the serial number
(1) is at the front on a sheet to the right of
the deflection sheave.
Serial number on
7 m section
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11 m section
(36 ft section)
11 m section 7 m section
(36 ft section) (23 ft section)
pG
Risk of accidents from falling two-stage swing-away lattice extension!
Always observe relevant centres of gravity shown in illustration below
when slinging and use suitable slinging material with sufficient lifting ca-
pacity; ➠ Transport dimensions and weights, p. 2-1.
In this way you prevent the lattice extension from slipping or falling
during installation or deinstallation and injuring people.
The distances are always measured from the centre of the fork elements.
For the 7 m two-stage swing-away lattice extension on its own, the dis-
16.02.2000
There are different initial states for rigging the lattice extension, depen-
ding on whether
The following table shows you which checklist describes the required rig-
ging work for your initial state.
CHECKLISTS:
Rigging the 11 m swing-away
Lattice extension is on the lattice extension; ➠ p.3-6.
side of the main boom Rigging the 18 m two-stage
Before swing-away lattice extension;
crane ➠ p. 3-17.
operation
CHECKLIST:
Lattice extension was Installing two-stage swing-
removed completely away lattice extension;
➠ p. 3-6.
CHECKLISTS:
Unrigging the 11 m swing-
Lattice extension should be away lattice extension;
folded at the side of the ➠ p. 3-13.
After main boom Unrigging the 18 m two-stage
crane
swing-away lattice extension;
operation ➠ p. 3-21.
CHECKLIST:
Lattice extension is to be Removing two-stage swing-
removed for on-road driving away lattice extension;
➠ p. 3-7.
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Requirements
– The truck crane is on outriggers or the main boom is placed on the
boom support.
– An auxiliary crane must be ready.
H
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If the lattice extension needs to be rigged in front of the main boom, see
point 7.
6. The other types of rigging work for folding up the lattice extension at
the side are described in the CHECKLIST: Unrigging 11 m swing-away lat-
tice extension from point 12 onwards, p. 3-14.
Requirements
– The truck crane is on outriggers or the main boom is placed on the
boom support.
– An auxiliary crane must be ready.
1. Carry out all of the rigging work for a rigged 11 m swing-away lattice
extension listed in the CHECKLIST: Unrigging 11 m swing-away lattice
extension up to and inclusive of point 9; ➠ S. 3-14.
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s
Operating instructions for lattice extension 2 084 545 en 3-7
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work
2. Carry out all of the rigging work for a rigged 18 m two-stage swing-
away lattice extension listed in the CHECKLIST: Removing 18 m two-
stage swing-away lattice extension up until and inclusive of point 10,
➠ p. 3-22.
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1. Prepare the truck crane for rigging the swing-away lattice extension;
➠ Preparing the truck crane for rigging and unrigging, p. 3-27.
2. Check that the lattice extension was unrigged properly and is in trans-
port condition; ➠ Checking transport condition with lattice extension folded
at the side, p. 3-31.
3. Fold out the run-up rail; ➠ Folding the run-up rail in/out, p. 3-32.
H If only the 11 m section is folded at the side of the main boom – proceed
as from point 7.
s
Operating instructions for lattice extension 2 084 545 en 3-9
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work
7. If only the 11 m sectionis folded at the side of the main boom, remove
connection between 11 m section and main boom (rear);
➠ Connections in the rear area, p. 3-38.
8. Swing 11 m section onto the main boom head; ➠ Swinging the lattice
extension onto the main boom head, p. 3 - 45.
9. Lock 11 m section onto the main boom head; ➠ Pin connections on the
main boom head, p. 3-39.
11. Unlock and remove connection between 11 m section and main boom
(front); ➠ Connections in the front area, p. 3-33.
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12. Swing 11 m section in front of the main boom; ➠ Swivelling the lattice
extension during rigging, p. 3-46.
17. Place hoist cable over both deflection sheaves and head sheave of the
11 m section; ➠ Positioning hoist cable, p. 3-52.
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s
Operating instructions for lattice extension 2 084 545 en 3 - 11
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work
18. Move anemometer from the head of the main boom to the head of
the 11 m section; ➠ Anemometer on lattice extension, p. 3-60.
19. Move lifting limit switch from the head of the main boom to the head
of the 11 m section; ➠ Lifting limit switch, p. 3-58.
20. Reeve the hoist cable on the hook block; ➠ Possible reeving methods on
the lattice extension, p. 3-54.
21. Attach lifting limit switch weight and guide hoist cable through the
weight; ➠ GMK 5100 Operating Instructions, part 2 Superstructure -
Rigging work.
00== 22. Enter the SLI code according to theLifting capacity table for the actual
rigging mode of the truck crane with the 11 m lattice extension, Setting
the rigging mode ➠ GMK 5100 Operating Instructions, part 2 Superstruc-
ture - Crane operation.
1. Prepare the truck crane for unrigging; ➠ Preparing the truck crane for rig-
ging and unrigging, p. 3 - 27.
2. Retract main boom completely and lower it into the horizontal positi-
on.
00== 3. Enter the SLI code according to the Lifting capacity table for the actual
rigging mode of the truck crane with the 11 m lattice extension, Setting
the rigging mode ➠ GMK 5100 Operating Instructions, part 2 Superstruc-
ture - Working with the crane.
4. Remove lifting limit switch weight and move lifting limit switch from
the head of the 11 m section to the head of the main boom; ➠ Lifting
limit switch, p. 3-58.
5. Unreeve the hoist cable from the hook block and remove from the lat-
tice extension; ➠ Possible reeving methods on the lattice extension, p. 3-54.
s
Operating instructions for lattice extension 2 084 545 en 3 - 13
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work
12. Swivel the 11 m section towards the main boom until the connection
between the main boom (in the front area) and the 11 m section enga-
ges; ➠ Swivelling the lattice extension during rigging, p. 3-46.
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14. Remove right-hand locking pin between 11 m section and main boom;
➠ Pin connections on the main boom head, p. 3-42.
15. Swivel the 11 m section on the run-up rail onto the main boom until
the connection between the 11 m section and the 7 m section enga-
ges; ➠ Connections in the middle area, p. 3-35.
17. If the 7 m section is not available, swivel the 11 m section on the run-
up rail onto the main boom and lock it there; ➠ Connections in the rear
area, p. 3-38.
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s
Operating instructions for lattice extension 2 084 545 en 3 - 15
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work
20. Fold in run-up rail; ➠ Folding the run-up rail in/out, p. 3-32.
16.02.2000
1. Prepare the truck crane for rigging the swing-away lattice extension;
➠ Preparing the truck crane for rigging and unrigging, p. 3-27.
2. Check that the lattice extension was unrigged properly and is in trans-
port condition; ➠ Checking transport condition with lattice extension folded
at the side, p. 3-31.
3. Fold out run-up rail; ➠ Folding the run-up rail in/out, p. 3-32.
5. Swivel lattice extension onto the main boom head; ➠ Swivelling the
lattice extension onto the main boom head, p. 3 - 45.
s
Operating instructions for lattice extension 2 084 545 en 3 - 17
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work
10. Pin 11 m section to left side of main boom head; ➠ Pin connections on
main boom head, p. 3-42.
18. Place hoist cable over both deflection sheaves and head sheave of the
7 m section; ➠ Positioning hoist cable, p. 3-52.
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19. Move anemometer from the head of the main boom to the head of
the 7 m section; ➠ Anemometer on lattice extension, p. 3-60.
20. Move lifting limit switch from the head of the main boom to the head
of the 7 m section; ➠ Lifting limit switch, p. 3-58.
21. Reeve the hoist cable on the hook block; ➠ Possible reeving methods on
the lattice extension, p. 3-54.
22. Attach lifting limit switch weight and guide hoist cable through the
weight; ➠ GMK 5100 Operating Instructions, part 2 Superstructure -
Rigging work.
23. Enter the SLI code according to theLifting capacity table for the actual
00== rigging mode of the truck crane with the 18 m lattice extension, Setting
the rigging mode ➠ GMK 5100 Operating Instructions, part 2 Superstruc-
ture - Crane operation.
1. Prepare the truck crane for unrigging; ➠ Preparing the truck crane for
rigging and unrigging, p. 3 - 27.
3. Enter the SLI code according to the Lifting capacity table for the actual
00== rigging mode of the truck crane with the 18 m two stage lattice exten-
sion, Setting the rigging mode ➠ GMK 5100 Operating Instructions, part 2
Superstructure - Crane operation.
4. Remove lifting limit switch weight and move lifting limit switch from
the head of the 7 m section to the head of the main boom; ➠ Lifting
limit switch, p. 3-58.
5. Unreeve the hoist cable from the hook block and remove from the lat-
tice extension; ➠ Possible reeving methods on the lattice extension, p. 3-54.
12. Remove the locking pin on the left-hand side between 7 m section and
11 m section; ➠ Pin connections on the lattice extension, p. 3-42.
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13. Swivel the 7 m section to the side of the 11 m section until the connec-
tion between the 7 m section and the 11 m section engages;
➠ Swivelling the lattice extension during rigging, p. 3-47.
➠ Connections in the middle area, p. 3-35.
16. Remove left pin between 11 m section and main boom head;
➠ Pin connections on the main boom head, p. 3-42.
17. Swivel the lattice extension towards the main boom until the connec-
tion between the main boom (in the front area) and the 11 m section
engages; ➠ Swivelling the lattice extension during rigging, p. 3-46.
s
Operating instructions for lattice extension 2 084 545 en 3 - 23
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work
19. Remove left pin between 11 m section and main boom head;
➠ Pin connections on the main boom head, p. 3-39.
20. Swivel the lattice extension on the run-up rail onto the main boom.
22. If the 7 m section has been removed, swivel the 11 m section on the
run-up rail onto the main boom and secure there with locking pin;
➠ Connections in the rear area, p. 3-38.
25. Fold in the run-up rail; ➠ Folding run-up rail in/out, p. 3-32.
Blank page
16.02.2000
H The data in this section also applies to the rigging of the boom extension.
Requirements for Before you rig a lattice extension or the boom extension, the following
rigging requirements must be met:
– The two-stage swing-away lattice extension is attached
to the side of the main boom and is in transport condition.
– The counterweight version required according to the Lifting capacity table
for the planned operation with the lattice extension is rigged.
– The truck crane is supported with the prescribed outrigger span for the
planned operation with the lattice extension according to the Lifting ca-
pacity table and is aligned horizontally.
– The main boom is completely retracted and has been lowered into hori-
zontal position.
– The telescoping cylinder is locked in telescopic section IV and is retract-
ed as far as possible just before the start of rigging so that all teles-
coping parts are fully retracted.
– If the truck crane is equipped with two hoists with additional equip-
ment, the hook block is unreeved on the hoist which is not used for
working with the lattice extension.
Requirements for Before you lower a lattice extension or the boom extension into a horizon-
unrigging tal position, the following requirements must be met:
capacity table.
s
Operating instructions for lattice extension 2 084 545 en 3 - 27
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work
Securing lattice If the truck crane is not well aligned, the lattice extension may swing out
extension with of its own accord when you remove the last connection that held the lat-
cord tice extension at the side of the main boom.
You must therefore secure the lattice extension before you begin with the
rigging work.
G
Risk of accidents from lattice extension swinging of its own accord
Always secure the lattice extension with a guide rope on the main boom
before removing any connections.
This will prevent the lattice extension from slipping off the run-up rail,
swinging around and knocking you off the carrier or injuring other per-
sons in the slewing range.
H If you are alone, secure the other end of the cord on the crane (e. g. on the
steps of the access ladder leading to the carrier). Leave enough play in
the cord that it is tight only when you swing the lattice extension onto the
main boom head later on.
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pS
Be careful not to damage the lattice extension and the main boom!
Always put the lattice extension into transport condition before driving
the truck crane with a lattice extension folded at the side or working with
the main boom.
Only then is the lattice extension secured against slipping.
This way you prevent the partly fastened lattice extension hitting the
main boom or the individual components of the lattice extension hitting
each other and becoming damaged.
The following paragraphs and the diagram show the necessary connecti-
ons for the transport condition with the lattice extension folded at the side
and removed.
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s
Operating instructions for lattice extension 2 084 545 en 3 - 29
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work
16.02.2000
Transport condi- The transport condition with the lattice extension folded at the side is
tion with lattice created when all of the following connections are established.
extension folded
at the side • Check the connections and establish them if necessary.
If 7 m section and 11 m section are folded at the side:
– The connection between 11 m section and main boom in the front area
is engaged (1) and the locking pin is inserted; ➠ Connections in the front
area, p. 3-33.
– The 7 m section is fastened to the run-up rail with a pin (6);
➠ Connections on the run-up rail, p. 3-36.
– The 7 m section and the 11 m section have been joined (2);
➠ Connections in the middle area, p. 3-35.
– The connections and those at the pivot point between the 7 m section
and the 11 m section have been established (3); ➠ Pin connections on the
lattice extension, p. 3-42.
– The 7 m section and main boom have been joined (4);
➠ Connections in the rear area, p. 3-37.
Transport condi- The transport condition for the removed lattice extension is created when
tion with remo- all of the following connections are established.
ved lattice exten-
sion • Check the connections and establish them if necessary.
– The connections and that at the pivot point between the 7 m section
and the 11 m section have been established (3); ➠ Pin connections on
the lattice extension, p. 3-42.
– The 7 m section and 11 m section have been joined (2);
➠ Connections in the middle area, p. 3-35.
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The run-up rail is folded out for rigging and folded back in for on-road
driving after derigging.
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The lattice extension is turned sideways to the main boom in folded position.
In this position there are four areas where various connections have to be
disconnected and reconnected again during rigging and unrigging:
G
Risk of accidents due to falling parts!
Always secure the pins both in the bearing points and in the holders
using retaining pins.
This prevents unsecured pins from becoming loose, falling out and cau-
sing injuries.
Connections in In the front area there is a connection between the 11 m section and the
the front area main boom.
s
Operating instructions for lattice extension 2 084 545 en 3 - 33
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work
G
Risk of accidents from lattice extension swinging of its own accord
Always secure the lattice extension with a guide rope on the main boom
before removing any connections.
This will prevent the lattice extension from slipping off the run-up rail,
swinging around and knocking you off the carrier or injuring other per-
sons in the slewing range.
Establishing connection
The two following points must be carried out
before you swivel the lattice extension onto
the run-up rail:
• Lift the lever (3) off the spring latch (2)
against the spring force and hold it.
• Push the spring latch in.
• Let the spring go. The lever moves down
into the end position.
• Swing the lattice extension onto the run-
up rail until the connection engages.
• Remove the locking pin (5) from the holder
(4),insert it in the bore in the bearing block
(1) and secure it with the retaining pin. The
connection is now established and secured.
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Connections in
the middle area
Connection between 7 m section and 11 m section
The connection must be made:
– for transportation,
– for installation and removal,
– when unrigging the 18 m two-stage swing-away lattice extension.
s
Operating instructions for lattice extension 2 084 545 en 3 - 35
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work
Connections The 7 m section can be fastened to the run-up rail with a pin.
on the run-up rail
The connection must be made:
– when unrigging the 18 m two-stage swing-away lattice extension,
– for operation with the 11 m swing-away lattice extension.
Establishing connection
• Swivel the entire 7 m section on the run-up
rail onto the main boom.
• Remove the pin (1) from the holder (2) and
use it to attach the 7 m section to the run-
up rail.
• Secure the pin with the retaining pin.
G
Risk of accidents from falling 7 m section!
Make sure the connection is established at the pivot point between the
7 m section and the 11 m section (➠ p. 3-42), before you remove the con-
nection between the 7 m section and the main boom. This will prevent
the 7 m section from falling down when releasing the connection.
Establishing connection
• Swivel the lattice extension into the main boom until the bearing point
(3) is aligned.
• Release the retaining pin and take one pin out of the retaining sheet (2).
• Insert the pin into the bearing points (3) and secure it with a retaining
pin.
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 3 - 37
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work
H
Connection between 11 m section and main boom
This connection does not apply to truck cranes that are supplied with an
18 m two-stage swing-away lattice extension.
Establishing connection
• Put the retaining strut onto the bearing
point (5) on the 11 m section.
• Fasten the retaining strut with a pin (4) and
secure the pin with a retaining pin.
The lattice extension and main boom head are connected on the bearing
points using pins. The pins can be found in holders on the lattice extensi-
on and are secured there with retaining pins.
G
Risk of accidents due to falling parts!
Always secure the pins both in the bearing points and in the holders
using retaining pins. This prevents unsecured pins from becoming loose,
falling out and causing injuries.
G
Risk of accidents from lattice extension swinging of its own accord
Always secure the lattice extension with a guide rope before removing
any connections.
This will prevent the lattice extension from swinging around of its own
accord and causing injury to you or other persons.
G
Risk of accidents from a falling lattice extension!
Be sure that the connection between the 11 m section and the main boom
has engaged and is secure before you release the connection on the right
side of the main boom head. This will prevent the lattice extension from
falling and causing injury to you or other persons.
s
Operating instructions for lattice extension 2 084 545 en 3 - 39
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work
Establishing con- For these connections you will find are three short pins and one long pin
H
nections in holders on the fixed part of the 11 m section.
The long pin is always placed last, into the bottom bearing point on the
left-hand side. Due to the lattice extension’s dead weight these bearing
points are not entirely in alignment and you cannot insert a short pin here.
Remove • Secure the lattice extension with a guide rope before removing any con-
connections nections.
G
Risk of accidents from a falling lattice extension!
Make sure the connection between the 11 m section and the main boom
is engaged and secured before removing the connection on the right-
hand side. This will prevent the lattice extension from falling and causing
injury to you or other persons.
The 11 m section and the 7 m section are connected on the bearing points
using pins. The pins are inserted into the 7 m section, at the rear of the
retaining sheet on the upper boom.
G
Risk of accidents due to falling parts!
Always secure the pins both in the bearing points and in the holders
using retaining pins. This prevents unsecured pins from becoming loose,
falling out and causing injuries.
G
Risk of accidents from 7 m section swinging of its own accord
Always secure the 7 m section with a guide rope before removing any
connections.
This will prevent the 7 m section from swinging around of its own accord
and causing injury to you or other persons.
G
Risk of accidents from falling 7 m section!
Be sure that the connections between the 7 m section and the main boom
(in the rear area) and between the 7 m section and the run-up rail have
been made before you release the connection on the right side of the pi-
vot point. In this way, you prevent the 7 m section from falling when this
connection is released and causing injury to you or others.
Connection on • Swivel the 7 m section in front of the 11 m section until the bearing
the left side points on the left side are in alignment.
Establishing connection
• Loosen the retaining pins and remove the
pins from the top of the retaining plate.
• Then insert the two pins (1) and (2) into
the bearing points on the left side and
secure the pins with retaining pins.
Removing the connection
• Remove the retaining pins and take pins
(1) and (2) out of the bearing points on the
left side.
• Insert both pins into the retaining sheet
and secure them with retaining pins.
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16.02.2000
Requirements – The lattice extension is in transport position when the lattice extension
is folded at the side; ➠ Checking transport condition, p. 3-31.
– The required connections among the individual lattice extension secti-
ons or the lattice extension sections and the main boom have been re-
moved.
Swinging lattice
extension
When swung, the lattice extension rolls on the run-up rail, turns around
the connection in the front area (2) and becomes makes contact at the
front at the bearing points (1).
• Swing the lattice extension until the bearing points (1) align and make
the swinging connection on the right side of the main boom head;
➠ p. 3-39.
• When unrigging, push the lattice extension onto the run-up rail until the
connection between the 11 m section and the main boom engages.
Secure the connection with the retaining pins; ➠ Connections in the front
area, p. 3-33.
16.02.2000
H This section describes the swinging of the lattice extension during rig-
ging. If you want to swing the lattice extension for unrigging, proceed in
the opposite order.
G
Risk of accidents from lattice extension swinging of its own accord
Always secure the lattice extension with a guide rope before you swing it
from the run-up rail. Make sure that there are no people or objects in the
slewing range of the lattice extension and always swing out the lattice
extension off the ground using a guide rope.
If a helper is holding the guide rope, he can now pull the lattice extension
from the run-up rail and swing it in front of the main boom head.
If you are alone and have attached the guide rope to the crane when
securing, the lattice extension will now only swing until the guide rope is
tight.
You can now use the guide rope to swing the lattice extension off the
floor and in front of the main boom head with.
You can set three different angles for the lattice extension (0°, 20° and 40°).
To set the angles, attach the lattice extension to the hoist cable and in-
cline by means of the hoist. The degree of the angle is determined by
H
securing pins, which are inserted or removed at the respective places.
If the length of lattice extension and the SLI permit it, you can also place
the lattice extension on the ground in order to make the pin connections.
In this case, the inclination sets itself during the raising of the main boom.
G
Risk of accidents and damage when inclining.
If the lattice extension is inclined in an incorrect fashion, it can lead to
accidents and to damage to the lattice extension and the hoist cable.
Therefore, only proceed according to the following instructions when in-
clining the lattice extension and observe all safety instructions.
Attaching lattice For rigging you need to attach the lattice extension to the hoist cable if it
extension to is to be inclined.
hoist cable
For unrigging you need to attach the lattice extension to the hoist cable in
order to pull the inclined lattice extension up to the 0°inclination.
• Guide the hoist cable over the deflection
sheave on the fixed part of the 11 m sec-
tion, along the left side of the lattice exten-
sion and up to the connection eye (1).
• Attach the cable end clamp (2) to the con-
nection eye.
• Place the hoist cable on the top of the lat-
tice extension in such a way that it cannot
become caught up.
S
Risk of damaging the hoist cable!
Always guide the hoist rope via the folded out deflection sheave in the
11 m section when you are attaching the lattice extension to the hoist
cable for adjusting the angle. This will keep the hoist cable from scraping
the lattice extension and prevent the forces in the hoist cable from in-
16.02.2000
pS
Risk of damage during telescoping!
Avoid telescoping the main boom as long as the hoist cable is attached to
the lattice extension. If telescoping is absolutely necessary, make sure
hoist cable will not tear by giving it sufficient slack.
Adjusting the This section decribes the procedure for adjusting the angle.
angle The required pin connections for the different angles are illustrated in the
following section; ➠ Pin connections for the angles, p. 3-50.
When rigging
• Lift the lattice extension with the hoist cable until the weight is taken off
the securing pins.
• Remove the retaining pins and knock out the securing pins; ➠ p. 3-50.
• Establish the pin connections required for this angle and secure all
securing pins with retaining pins; ➠ p. 3-50.
• Incline the lattice extension with the hoist into the required angle.
When unrigging
• Using the hoist cable, pull the lattice extension to a 0° angle.
• Give a little more hoist cable and lower the main boom if necessary for
better access to the pin connections.
• Remove the retaining pins and knock out the securing pins; ➠ p. 3-50.
pS
Risk of damaging the hoist cable when lowering!
If you have pulled the lattice extension as far as possible into the 0° posi-
tion with the hoist cable, you always have to leave some hoist cable be-
fore you lower the main boom. In this position the lattice extension can
no longer compensate the radius modification by inclining, the hoist
cable is weighted when lowered and may tear.
• Make the necessary pin connections for the 0° angle and secure all se-
curing pins with retaining pins.
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 3 - 49
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work
Pin connections On each side there is a retaining pin in the strut above the point of adjust-
for the angle ment which is used for setting the angle of inclination.
The retaining pins are inserted into different bores, depending on the de-
gree of inclination of the lattice extension.
G
Risk of accidents from lattice extension folding down!
Always secure the lattice extension with the hoist cable before you knock
out pins for the angle. This will prevent the lattice extension suddenly
folding down and injuring you or other people.
0°angle
On both sides the securing pins are inserted
into the bores (1) and secured with securing
pins.
The bores (2) remain open.
20°angle
On both sides the securing pins are inserted
into the bores (2) and secured with securing
pins.
The bores (1) remain open.
40°angle
On both sides the bores (1) and (2) remain
free. The securing pins are inserted in the
holders (3) and are secured with retaining
pins.
G
Risk of accidents from non-secured securing pins!
Always secure the securing pins in the holders (3) with retaining pins.
This prevents the non-secured pins from falling out of the holders and
causing injuries.
16.02.2000
To prevent the hoist cable dragging on the main boom or the lattice exten-
sion during operation with the lattice extension, the hoist cable is guided
via a deflection sheave.
You need to fold the deflection sheave out for operation with the lattice
extension as well as for operation with the boom extension.
For transportation, fold the deflection sheave back in again.
G
Risk of crushing!
Always hold the deflection sheave by the crosshead on the top when
removing the pin. You might get your fingers crushed if you hold the
sheave by the side plate.
G
Risk of accidents due to falling parts!
Always secure the hoist cable holding rollers and rods with retaining pins.
This prevents elements coming loose, falling down and injuring people.
When setting an When setting an angle of 40° or 20°, positioning and removing the hoist
angle of cable is done in two steps:
20° or 40°
For positioning:
– Begin by placing hoist cable over deflection sheave in the fixed part of
the 11 m section only and attach to front of the connection eye.
– After having set the angle, disconnect hoist cable from connection eye
and guide over the front deflection sheave and head sheave.
For removal:
– Begin by removing hoist cable from head sheave and front deflection
sheave and fasten to connection eye.
– After having set 0°angle, disconnect hoist cable from connection eye
and take it off the deflection sheave in the fixed part of the 11 m section.
16.02.2000
Positioning hoist • Remove the hoist cable holding rollers and rods (1).
rope
• Guide the hoist rope via the deflection sheaves (4), (3) and via the head
sheave (2) on the 11 m section or on the 18 m section.
• Put all hoist cable holding rollers and rods back in place and secure
these with retaining pins.
• Attach the hook tackle or the hook block. The hoist rope may now, de-
pending on the length of lattice extension, be reeved once or twice;
➠ p. 3-54.
s
Operating instructions for lattice extension 2 084 545 en 3 - 53
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work
The hoist cable can be reeved at the most twice on the 11 m swing-away
lattice extension.
Reeving the hoist rope into the hook block; ➠ GMK 5100 Operating Instruc-
tions, part 2 Superstructure - Rigging work.
16.02.2000
The SLI, the lifting limit switch and the lowering limit switch are connec-
ted via the electrical connection on the lattice extension.
s
Operating instructions for lattice extension 2 084 545 en 3 - 55
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work
16.02.2000
The functions Raise hoist, extend main boom, extend main boom and Lower main
boom are monitored during operation with the lattice extension by the
lifting limit switch on the lattice extension and are switched off when the
H
lifting limit switch is actuated.
The same lifting limit switch is used for lattice extension and main boom.
Overriding con- For operation with the lattice extension you must remove the lifting limit
nection on main switch on the main boom and override the connection.
boom
• Insert the short-circuit plug (1) in the
socket for the connection of the lifting limit
switch.
The connection is now overridden.
On 11 m swing-
away lattice
extension
• Place the lifting limit switch (3) in the hol-
der (4) and secure it
with a retaining pin.
• Remove the short-circuit plug (2) from the
socket (1).
• Connect the lifting limit switch on the sock-
et (1).
On the 18 m two-
stage swing-
H
away lattice ex-
tension
H
On 11 m swing-away
The same anemometer is used for lattice extension and main boom.
lattice extension
• Attach the anemometer (3) to the holder
(2) on the head of the 11 m section and
secure it with a retaining pin.
• Insert the plug (1) of the connecting cable
in the distribution box on the head of the
11 m section.
• Check for freedom of movement.
The anemometer must return to a vertical
position after being swung outwards.
• When unrigging close the socket on the
distribution box with the protective cap.
On the 18 m two-
stage swing-away
lattice extension
• Attach the anemometer (1) to the holder
(2) on the head of the 7 m section and se-
cure it with a retaining pin.
• Insert the plug (3) of the connecting cable
in the distribution box on the head of the 7
m section.
• Check for freedom of movement.
The anemometer must return to a vertical
position after being swung outwards.
• When unrigging close the socket on the
distribution box with the protective cap.
H
16.02.2000
You must remove the anemometer before unrigging the lattice extension.
G
Only attach the lattice extension in such a way that it is positioned in the
centre of gravity and always use lifting gear with sufficient lifting capaci-
ty. This prevents the lattice extension falling and injuring people while
loading; ➠Centres of gravity for slinging, p. 3-4.
• Check that all the required connections for transport condition are
established; ➠ Checking transport condition with removed lattice extension,
p. 3-31.
pS
Risk of damaging the lattice extension!
Always secure the lattice extension by tying it down with suitable belts
when it is transported on a separate vehicle. This prevents the two-stage
swing-away lattice extension tipping and becoming damaged during
transportation.
16.02.2000
Blank page
16.02.2000
3.6 Raising and setting down the main boom with rigged
H
lattice extension
The information in this section also applies to raising and setting down
H
the main boom with a rigged boom extension.
To raise and set down the main boom with a rigged lattice extension the
main boom must be fully retracted because the SLI then automatically
switches to the rigging program.
– The SLI code for the actual rigging mode is set on the SLI with the
00== rigged lattice extension; ➠ GMK 5100 Operating Instructions, part 2
Superstructure - Crane operation.
– The current reeving of the hoist cable on the lattice extension is entered.
“! – Apart from the hook block there is no load on the lattice extension.
Blank page
16.02.2000
pS
The main boom may become overloaded!
If you telescope the main boom with a rigged lattice extension or boom
extension, you must not rotate the superstructure at the same time.
This prevents the main boom becoming subject to additional side forces
and increased vibration and becoming overloaded.
Telescoping with a load is released by the SLI only for loads which are be-
low the values of the rigging programmes.
Telescoping with a rigged lattice extension is released by the SLI only if
the main boom is raised to an angle of approx. 75° - 80° (the exact angle
depends on the length of the lattice extension ➠ Rigging programs in the
lifting capacity table).
If the main boom angle is too small for telescoping with the rigged lat-
tice extension angle, the SLI shows the corresponding error message.
Blank page
16.02.2000
H
3.8 Operation with the lattice extension
The information in this section also applies to operation with the boom ex-
tension. Observe the following safety instruction before working with the
boom extension.
G
Risk of overturning when working with the boom extension!
While you are working with the boom extension, make sure there is no
hook block reeved on the main boom.
It is not permitted to work with the main boom if the boom extension is
rigged.
H If a hook block is reeved on the main boom during operation with the lat-
tice extension, the loads given in the Lifting capacity tables decrease. The
values which must be deducted from the load capacities depend on the
length of the lattice extension and the weight of the hook block and are
H
entered in their own table in the Lifting capacity tables.
Operation with the lattice extension and the boom extension is monitored
by the SLI.
During work with the lattice extension, an SLI shutdown may occur for the
same reasons as applied to operation with the main boom; ➠ p. 12-26.
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 3 - 67
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.8 Operation with the lattice extension
Strong winds can overstrain the truck crane. Therefore, closely observe
the instructions in the Effect of wind on crane operation, p. 12-31.
16.02.2000
G
Risk of accidents due to overloading!
Lifting a load with two hooks is permissible only if the following instruc-
tions and illustrations are observed!
If these instructions are not observed, accidents could occur due to indivi-
dual parts of the truck crane being overloaded! The SLI then no longer
provides protection.
Two-hook operation with the boom extension is not permitted!
G
Risk of accidents due to overloading!
The load must always be lifted completely with the weakest part first
(lattice extension).
H You can find the position and function of the required operating instru-
ments in the supplied Operating Instructions for the GMK 5100.
3.9.1 Requirements
G
Risk of accidents due to overloading!
The reeving on the main boom must be equal to or greater than that on
the lattice extension!
If this condition is not fulfilled, the main hoist cable and main hoisting
gear will become overloaded.
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 3 - 69
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.9 Turning loads with the lattice extension
H
For two-hook operation, both hoists must be activated on the SLI.
It is advisable to enter the reevings for both hoists at the start. The values
are stored and called up directly when switching hoisting gears. This eli-
minates the need for input later during operation. Proceed as follows:
• In the display Reeving, enter the quantity of reeved cable of the main
§ hoist cable on the main boom.
Now the reeving for the main hoist is stored and you can switch to the au-
xiliary hoist.
• In the display Reeving, enter the quantity of reeved rope on the auxiliary hoist
! cable of the lattice extension.
Now the reeving for the auxiliary hoist is also stored and you can switch
on the main hoist.
16.02.2000
• Switch the main hoist on by pressing the Main hoist shutdown rocker
ü switch up.
On the display lamps Hoists, lamp II is now lit for the auxiliary hoist and
lamp I is flashing for the main hoist.
• Set the SLI code for operation with the telescopic swing-away lattice ex-
11== tension which is valid for the current rigging mode of the truck crane.
The SLI is thus set for two-hook operation; it now takes into consideration
the reeving for the auxiliary hoist and the lifting capacity tables for the lat-
H
tice extension.
In two-hook operation the loads given in the Lifting capacity table are redu-
ced by the weight of both reeved hook blocks.
Turning a load To turn loads, proceed only in the manner described as follows.
pS
Keep the acceleration force as low as possible during two-hook operation.
Therefore move the load at the lowest possible speed!
H If the load is on two hooks, there will be slight differences in the Actual
load display. However, the differences are on the safe side with regard to
H
SLI shutdown.
If the load is on two hooks, you must not change the SLI code to Operation
with main boom; it must be set to Operation with the lattice extension through-
out the lifting process.
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 3 - 71
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.9 Turning loads with the lattice extension
C0183
C0184
• Slacken the hoist cable on the lattice extension until the load is only
hanging from the hook block on the main boom.
16.02.2000
G
Risk of accidents!
It is forbidden to move the truck crane with a load on the hook.
Put the load down before you move the truck crane.
Secure the hook block so that it cannot swing.
G
Risk of overturning!
Before a rigged crane can be driven, the superstructure must be locked
and the slewing gear permanent brake must be engaged.
The route must be a flat, even surface. The level adjustment system can-
not compensate for uneven surfaces. If the surface pressure of the tyres
exceeds the permissible load on the ground, the surface pressure must be
increased using packing made of durable material (e.g. wooden planks).
pS
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ GMK 5100 Operating Instructions, part 1 Carrier - Technical data.
Do not reduce the tyre pressure!
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 3 - 73
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed
The vehicle may only be moved if certain conditions are met. The boom
may have to be moved to a specified position, depending on the installed
counterweight.
pS
Damage may occur to the axle lines!
Always move the boom to the prescribed position before you move the
rigged truck crane. The permitted load on the axle lines will be exceeded
if the boom is in a position which deviates from the prescribed position.
• Set the appropriate SLI code for the rigging mode on the safe load indi-
00== cator. The SLI codes can be found in the Lifting capacity table.
• Move the boom into the prescribed position. The prescribed boom posi-
tion can be found in the following tables.
G
Risk of accidents if SLI is overridden!
Always set the SLI rigging code corresponding to the current rigging
mode when you derrick the main boom into the prescribed position. Do
not override the SLI; the prescribed positions in the following tables are
all within the areas permitted according to the Lifting capacity tables.
The truck crane safe load indicator does not function when the SLI is over-
ridden!
16.02.2000
11 m swing-away The following table only applies if the 11 m swing-away lattice extension
lattice extension is rigged. Tables applying if 18 m two-stage swing-away lattice extension
is rigged; ➠ p. 3-76.
Tables applying if boom extension is rigged; ➠ p. 4-21.
H
Counter Telescoping
The axle loads specified in the following tables refer to a driving mode
with the basic unit and 20 t hook tackle reeved on the lattice extension,
hook blocks must be unreeved.
1)
Boom position at rear = 0° position, boom over
truck crane rear edge
Boom position at front = 180° position, boom over
driver’s cab
2)
The indicated values apply to a 20° inclination of the lattice extension.
For other inclinations the values change slightly.
Axle load front: on the 1st, 2nd and 3rd axle line respectively
rear: on the 4th and 5th axle line respectively
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 3 - 75
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed
18 m two-stage The following table only applies if the 18 m two-stage swing-away lattice
swing-away latti- extension is rigged.
ce Tables applying if 11 m two-stage swing-away lattice extension is rigged;
extension ➠ p. 3-75.
Tables applying if boom extension is rigged; ➠ p. 4-21.
H
Counter Telescoping
The axle loads specified in the following tables refer to a driving mode
with the basic unit and 8 t hook tackle reeved on the lattice extension,
hook blocks must be unreeved.
1)
Boom position at rear = 0° position, boom over
truck crane rear edge
Boom position at front = 180° position, boom over
driver’s cab
2)
The indicated values apply to a 20° inclination of the lattice extension.
For other inclinations the values change slightly.
Axle load front: on the 1st, 2nd and 3rd axle line respectively
rear: on the 4th and 5th axle line respectively
16.02.2000
Locking the su- Before the truck crane is moved, the superstructure must be locked to the
perstructure and carrier; ➠ GMK 5100 Operating Instructions, part 2 Superstructure - Crane ope-
engaging the sle- ration.
wing gear perma-
nent brake
• Lock the superstructure; the indicator lamp Superstructure locked must be
! lit.
• Apply the slewing gear permanent brake and switch off the Slewing func-
Y tion to prevent inadvertent operation.
To do this push down the Slewing gear permanent brake rocker switch. The
Slewing gear permanent brake applied indicator lamp lights up when the
H
slewing gear permanent brake is applied.
If the crane engine stops the slewing gear permanent brake is automa-
tically applied.
Retracting the • Retract the outrigger cylinders until the wheels are just above the
outrigger ground.
G
Risk of overturning!
Make sure that the truck crane does not overturn when the outriggers are
being retracted!
Retract all the outrigger cylinders as uniformly as possible!
Switching over
the suspension
locking system
• Switch the suspension locking system off. To do this push up the
u Suspension locking system rocker switch. The Suspension locking system indi-
cator lamp must go out.
• Retract the outrigger cylinders until the truck crane is approximately at
on-the-road level.
• Switch the suspension locking system back on again. To do this push
u down the Suspension locking system rocker switch. The Suspension locking
system indicator lamp lights up when the suspension system is locked.
• Continue to retract the outrigger cylinders.
G
Risk of overturning!
To reduce the risk of the crane overturning do not raise the outrigger
16.02.2000
pads more than 5 to 10 cm off the ground. Leave the outrigger beams ex-
tended.
s
Operating instructions for lattice extension 2 084 545 en 3 - 77
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed
Switch on sepa- Before driving with the rigged crane you must switch on the separate
rate steering steering:
C0018
pS
Damage may occur to steering linkage!
Before driving with the rigged crane always switch on separate steering
and steer the truck crane only when the vehicle is moving.
If separate steering is switched off or if you steer with the vehicle sta-
tionary the steering linkage may become damaged.
Driving
pS
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ GMK 5100 Operating Instructions, part 1 Carrier - Technical data.
Do not reduce the tyre pressure!
H The wind speed must be checked before the rigged truck crane is moved!
The same maximum permissible wind speeds apply as when working
with the crane; ➠ GMK 5100 Operating Instructions, part 2 Superstructure -
Crane operation.
• Switch the transfer case to off-the-road gear to move the truck crane;
➠ GMK 5100 Operating Instructions, part 1 Carrier - Driving the truck crane.
• Select a low gear on the transmission; ➠ GMK 5100 Operating Instruc-
tions, part 1 Carrier - Driving the truck crane.
• Drive at only a very low speed!
• The turning radius should be as large as possible when turning corners!
16.02.2000
• Steer the truck crane only when it is moving and avoid sudden steering
movements!
When the surface is uneven the truck crane must be raised with the outrig-
ger cylinders, horizontally aligned and then re-lowered;
➠ GMK 5100, part 2 Superstructure - Rigging work
and part 1 - Driving the truck crane.
Extending the The truck crane must be on outriggers before beginning work with the
outrigger crane; GMK 5100 Operating Instructions, part 2 Superstructure - Rigging work.
G
Risk of overturning!
The truck crane must be raised until no wheels touch the ground!
16.02.2000
H
3.11 Malfunction when working with lattice extension!
The lifting limit switch does The lifting limit switch is not Switch on the lifting limit
not function connected switch; ➠ Lifting limit switch,
p. 3-58.
No electrical connection Establish electrical
between boom head and connection; ➠
lattice extension or between Establishing/disconnecting
11 m section and 7 m section electrical connection on the lattice
extension, p. 3-55.
Lifting limit switch on main Override lifting limit switch on
boom head not overridden the main boom head;
➠ p. 3-58.
When operating with an 18 m Insert short-circuit plug;
lattice extension or boom ➠ p. 3-57.
extension the short-circuit
plug is not inserted on the
head of the 12.5 m section.
Main boom cannot be tele- Main boom is raised to an Raise main boom to required
scoped when lattice extensi- angle at which telescoping is angle;
on or boom extension is rig- not permitted ➠ Telescoping with rigged lattice
ged extension, p. 3-65.
16.02.2000
Provide protection for the following electrical parts during cleaning work:
– the control box on the fixed part of the 11 m section (1) and
H
– the control box at the front of the 7 m section (2)
Also observe all the instructions contained in the chapter titled Cleaning
work of the Maintenance Manual for the GMK 5100.
16.02.2000
H For lubricating the pins and support rollers, use the same grease as stated
in the Maintenance Manual for attach pins and socket pins; ➠ GMK 5100
Maintenance Manual, Overview of maintenance work - Maintenance plan M1.
Pins Lubricate all attach, securing and retaining pins. These are
Support rollers There are two support rollers on the lattice extension that need to be lubri-
cated.
4.1.1 Identification
S
Operate the truck crane only with those sections of the boom extension
which have the same serial number as the crane.
The SLI is only set for this boom extension.
This prevents malfunctions and damage.
H For technical reasons a truck crane may only be set with one boom exten-
sion.
If you wish to use the boom extension on several GROVE truck cranes, the
parts of the boom extension must be adjusted for these cranes and label-
led with all of the respective serial numbers.
S
Have the adjustment of the boom extension carried out only by your local
GROVE Product Support!
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 4-1
GMK 5100
Boom extension (additional equipment)
4.1 Identification and slinging points
G
This section shows the slinging points on the 8 m sections.
Attach the sections on these slinging points only. They will then automat-
ically have the correct centre of gravity. Only use lifting gear with suffi-
cient load bearing capacity; ➠ Transport dimensions and weights, p. 2-1.
16.02.2000
26 m boom extension
(85 ft boom extension)
34 m boom extension
(112 ft boom extension)
Blank page
16.02.2000
Requirements
– The truck crane is on outriggers or the main boom is placed on the
boom support.
– An auxiliary crane must be ready.
1. Prepare the truck crane for unrigging; ➠ Preparing the truck crane for rig-
ging and unrigging, p. 3-27.
2. If the lattice extension is folded up at the side of the main boom, re-
move the lattice extension; ➠ CHECKLIST: Removing two-stage swing-
away lattice extension, p. 3-7.
ps
Operating instructions for lattice extension 2 084 545 en 4-5
GMK 5100
Boom extension (additional equipment)
4.3 Check lists for rigging work
12. Place hoist cable over all the deflection sheaves and the head sheave
of the 7 m section; ➠ Positioning/removing hoist cable, p. 4-16.
14. Move anemometer (additional equipment) from the head of the main
boom to the head of the 7 m section; ➠ Anemometer on lattice extension,
p. 3-60.
15. Move lifting limit switch from the head of the main boom to the head
of the 7 m section; ➠ Lifting limit switch, p. 3-58.
16. Reeve the hoist cable on the hook block; ➠ Possible reeving methods on
the lattice extension, p. 3-54.
17. Attach lifting limit switch weight and guide hoist cable through the
weight; ➠ GMK 5100 Operating Instructions, part 2 Superstructure -
Crane operation.
16.02.2000
ps
Operating instructions for lattice extension 2 084 545 en 4-7
GMK 5100
Boom extension (additional equipment)
4.3 Check lists for rigging work
18. Enter SLI code according toLifting capacity table for the actual rigging
00== mode of the truck crane with the 26 m or 34 m boom extension,
Setting the rigging mode ➠ GMK 5100 Operating Instructions, part 2 Super-
structure - Crane operation.
Requirements
– The truck crane is on outriggers or the main boom is placed on the
boom support.
– An auxiliary crane must be ready.
1. Prepare the truck crane for unrigging; ➠ Preparing the truck crane for rig-
ging and unrigging, p. 3-27.
3. Enter the SLI code according to the Lifting capacity table for the actual
00== rigging mode of the truck crane when the extension boom is rigged,
Setting the rigging mode ➠ GMK 5100 Operating Instructions, part 2 Super-
structure - Crane operation.
4. Remove lifting limit switch weight and move lifting limit switch from
the head of the 7 m section to the head of the main boom; ➠ Lifting
limit switch, p. 3-58.
16.02.2000
5. Reeve out hoist cable from the hook block; ➠ Possible reeving methods
on the lattice extension, p. 3-54.
9. Remove hoist cable and fold in deflection sheaves on all parts of the
boom extension; ➠ Positioning/removing hoist cable, p.4-16.
➠ Folding deflection sheaves on 11 m section in/out, p. 3-51.
➠ Folding deflection sheaves on 8 m section in/out, p.4-15.
ps
Operating instructions for lattice extension 2 084 545 en 4-9
GMK 5100
Boom extension (additional equipment)
4.3 Check lists for rigging work
11. Remove the locking pins on the left-hand side between 7 m section
and 11 m section;
➠ Pin connections on the lattice extension, p. 3-42.
12. Swivel the 7 m section onto the 11 m section side until the connection
between the two sections engages;
➠ Swivelling the lattice extension during rigging, p. 3-47.
➠ Connections in the middle area, p. 3-35.
– In order to rig the 26 m boom extension you must install the 8 m secti-
on with support roller in front of the main boom head.
– To rig the 34 m boom extension you must also mount the 8 m section
without support roller in front of the 8 m section with support roller.
Installing 8 m sections
• Sling the 8 m section with support roller
on an auxiliary crane and lift it in front of
the main boom head so that the bearing
points (2) and (3) align on both sides.
• Insert the securing pins on both sides into
the bearing points (2) and (3).
• Secure all pins with retaining pins.
• For the 34 m boom extension, install the
second 8 m section in the same way as the
first 8 m section.
Removing 8 m sections
• Sling the 8 m section on an auxiliary crane and lift it until the weight
has been taken off the bearing points (2) and (3).
• Release the pins and knock them out of the bearing points (2) and (3) on
both sides.
• Insert the pins into the holders on the foot of the 8 m sections and se-
16.02.2000
This section describes the installation and removal of the folded two-sta-
ge swing-away lattice extension.
You can also install the two-stage swing-away lattice extension which has
been folded in front of the other in front of an 8 m section (e. g. when you
are changing directly from the 18 m two-stage swing-away lattice exten-
sion to a boom extension).
Installation
• Sling the two-stage swing-away lattice
extension onto an auxiliary crane;
➠ Centres of gravity for slinging, p. 3-4.
• Lift the two-stage swing-away lattice exten-
sion in front of the 8 m section so that the
bearing points (2) and (3) align on both
sides.
• Insert the securing pins on both sides into
the bearing points (2) and (3).
• Secure all pins with retaining pins.
Removing
• Sling the two-stage swing-away lattice extension onto an auxiliary cra-
ne; ➠ Centres of gravity for slinging, p. 3-4.
• Lift the two-stage swing-away lattice extension until the load has been
relieved from the bearing points.
• Release the pins and knock them out of the bearing points (2) and (3) on
both sides.
• Insert the pins into the holders on the 11 m section and secure them
16.02.2000
Connections on
the 8 m sections
At the rear of the 8 m sections there is a
cable with a plug (3).
You can connect the cable to the main boom
head or a second 8 m section.
ps
Operating instructions for lattice extension 2 084 545 en 4 - 13
GMK 5100
Boom extension (additional equipment)
4.4 Description of rigging work
16.02.2000
This section describes only the folding in and out of the deflection sheave
on the 8 m section. To fold the deflection sheaves in and out on the
11 m section ➠ Folding out/in deflection sheaves on the 11 m section, p. 3-51.
If you intend to work with the boom extension you need to fold out the
deflection sheaves on the rear 8 m sections.
Fold the deflection sheave in for transportation.
G
Risk of accidents due to falling parts!
Always secure the hoist cable holding rollers and rods with retaining pins.
This prevents elements coming loose, falling down and injuring people.
When setting an When setting an angle of 20° or 40°, positioning and removing the hoist
angle of cable is done in two steps:
20° or 40°
For positioning:
– Begin by placing the hoist cable over the deflection sheaves in the 8 m
section and in the fixed part of the 11 m section and attach to the con-
nection eye at the front.
– After having set the angle, disconnect hoist cable from connection eye
and guide over the front deflection sheave in the 11 m section and over
the head sheave.
For removal:
– Begin by removing hoist cable from head sheave and front deflection
sheave in the 11 m section and fasten to connection eye.
– After having set the 0° angle, disconnect hoist cable from connection
eye and take it off the deflection sheaves in the fixed part of the 11 m
section and the 8 m section.
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26 m boom extension
34 m boom extension
Blank page
16.02.2000
G
Risk of accidents!
It is forbidden to move the truck crane with a load on the hook.
Put the load down before you move the truck crane.
Secure the hook block so that it cannot swing.
G
Risk of overturning!
Before a rigged crane can be driven, the superstructure must be locked
and the slewing gear permanent brake must be engaged.
The route must be a flat, even surface. The level adjustment system can-
not compensate for uneven surfaces. If the surface pressure of the tyres
exceeds the permissible load on the ground, the surface pressure must be
increased using packing made of durable material (e.g. wooden planks).
S
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ p. 6-8.
Do not reduce the tyre pressure!
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 4 - 19
GMK 5100
Boom extension (additional equipment)
4.5 Driving with rigged crane and lattice extension or boom extension installed
The vehicle may only be moved if certain conditions are met. The boom
may have to be moved to a specified position, depending on the installed
counterweight.
S
Damage may occur to the axle lines!
Always move the boom to the prescribed position before you move the
rigged truck crane. The permitted load on the axle lines will be exceeded
if the boom is in a position which deviates from the prescribed position.
• Set the appropriate SLI code for the rigging mode on the safe load indi-
00== cator. The SLI codes can be found in the Lifting capacity table.
• Move the boom into the prescribed position. The prescribed boom po-
sition can be found in the following tables.
G
Risk of accidents if SLI is overridden!
Always set the SLI rigging code corresponding to the current rigging
mode when you derrick the main boom into the prescribed position. Do
not override the SLI; the prescribed positions in the following tables are
all within the areas permitted according to the Lifting capacity tables.
The truck crane safe load indicator does not function when the SLI is over-
ridden!
16.02.2000
26 m boom The following table only applies if the 26 m boom extension is rigged.
extension Tables applying if 34 m boom extension is rigged; ➠ p. 4-22.
Tables applying if two-stage swing-away lattice extension is rigged;
➠ p. 3-75.
H The axle loads specified in the following tables refer to a driving mode
with the basic unit and 8 t hook tackle reeved on the lattice extension,
hook blocks must be unreeved.
1)
Boom position at rear = 0° position, boom over truck crane rear edge
Boom position at front = 180° position, boom over driver’s cab
2)
The indicated values apply to a 20° inclination of the lattice extension.
For other inclinations the values change slightly.
Axle load front: on the 1st, 2nd and 3rd axle line respectively
rear: on the 4th and 5th axle line respectively
16.02.2000
ps
Operating instructions for lattice extension 2 084 545 en 4 - 21
GMK 5100
Boom extension (additional equipment)
4.5 Driving with rigged crane and lattice extension or boom extension installed
34 m boom The following table only applies if the 34 m boom extension is rigged.
extension Tables applying if 26 m boom extension is rigged; ➠ p. 4-21.
Tables applying if two-stage swing-away lattice extension is rigged;
➠ p. 3-75.
H
Counter Telescoping
The axle loads specified in the following tables refer to a driving mode
with the basic unit and 8 t hook tackle reeved on the lattice extension,
hook blocks must be unreeved.
1)
Boom position at rear = 0° position, boom over truck crane rear edge
Boom position at front = 180° position, boom over driver’s cab
2)
The indicated values apply to a 20° inclination of the lattice extension.
For other inclinations the values change slightly.
Axle load front: on the 1st, 2nd and 3rd axle line respectively
rear: on the 4th and 5th axle line respectively
Locking the su- Before the truck crane is moved, the superstructure must be locked to the
perstructure and carrier; ➠ GMK 5100 Operating Instructions, part 2 Superstructure - Crane
engaging the operation.
slewing gear per-
manent brake
• Lock the superstructure; the indicator lamp Superstructure locked must illu-
16.02.2000
! minate.
• Apply the slewing gear permanent brake and switch off the Slewing func-
Y tion to prevent inadvertent operation.
To do this push down the Slewing gear permanent brake rocker switch. The
Slewing gear permanent brake applied indicator lamp lights up when the
H
slewing gear permanent brake is applied.
If the crane engine stops the slewing gear permanent brake is automat-
ically applied.
Retracting the • Retract the outrigger cylinders until the wheels are just above the
outrigger ground.
G
Risk of overturning!
Make sure that the truck crane does not overturn when the outriggers are
being retracted!
Retract all the outrigger cylinders as uniformly as possible!
Switching over
the suspension
locking system
• Switch the suspension locking system off. To do this push up the Sus-
u pension locking system rocker switch. The Suspension locking system indica-
tor lamp must go out.
• Retract the outrigger cylinders until the truck crane is approximately at
on-the-road level.
• Switch the suspension locking system back on again. To do this push
u down the Suspension locking system rocker switch. The Suspension locking
system indicator lamp lights up when the suspension system is locked.
• Continue to retract the outrigger cylinders.
G
Risk of overturning!
To reduce the risk of the crane overturning do not raise the outrigger
pads more than 5 to 10 cm off the ground. Leave the outrigger beams
extended.
Switching on Before driving with the rigged crane you must switch on the separate
separate steering steering:
C0018
s
Operating instructions for lattice extension 2 084 545 en 4 - 23
GMK 5100
Boom extension (additional equipment)
4.5 Driving with rigged crane and lattice extension or boom extension installed
S
Damage may occur to steering linkage!
Before driving with the rigged crane always switch on separate steering
and steer the truck crane only when the vehicle is moving.
If separate steering is switched off or if you steer with the vehicle statio-
nary the steering linkage may become damaged.
Driving
S
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ Checking the tyres, p. 6-8.
Do not reduce the tyre pressure!
H The wind speed must be checked before the rigged truck crane is moved!
The same maximum permissible wind speeds apply as when working
with the crane; ➠ GMK 5100 Operating Instructions, part 2 Superstructure -
Crane operation.
Extending the The truck crane must be on outriggers before beginning work with the
outrigger crane; GMK 5100 Operating Instructions, part 2 Superstructure - Rigging work.
16.02.2000
H For lubricating the pins, use the same grease as stated in the Maintenance
Manualfor attach pins and socket pins; ➠ GMK 5100 Maintenance Manual,
Overview of maintenance work - Maintenance plan M1.
Blank page
16.02.2000
5.1 Identification
The auxiliary single-sheave boom top is designed for the truck crane it
was delivered with. It has the same serial number as the truck crane.
S
Operate the truck crane only with the auxiliary single-sheave boom top
that has the identical serial number.
If you wish to use the boom top on several GROVE truck cranes, it needs
to be adapted to the corresponding crane and marked with all the serial
numbers.
S
The auxiliary single-sheave boom top should only be adjusted by your
local GROVE Product Support!
Blank page
16.02.2000
G
Risk of accidents if the boom top should fall off!
During installation and removal, always use the proper materials with
sufficient load bearing capacities, ➠ Transport dimensions and weights,
p. 2-1.
On the left side of the main boom head there is a holding device.
When installing, the holding device is connected to the front bore holes (1).
The boom top is mounted to a holding device on the left side of the main
boom head.
When removing, the locking pins are first taken out of the front bore holes
(1) in the holding device.
16.02.2000
On the left side of the main boom head there is a holding device.
In transport position, the boom top is connected to the rear bore holes (1)
on the holding device.
On the left side of the main boom head there is a holding device.
In working position, the auxiliary single-sheave boom top is attached to
the main boom head at both bore holes.
In operation
During transport
Anemometer • The anemometer is connected to the main boom head as it is for opera-
tion with the main boom; ➠ GMK 5100 Operating instructions, Part 2 Super-
16.02.2000
G
Risk of accidents due to overloading!
Lifting a load with two hooks is permissible only if the following instruc-
tions and illustrations are observed!
If these instructions are not observed, accidents could occur due to indivi-
dual parts of the truck crane being overloaded! The SLI then no longer
provides protection.
Two-hook operation with the boom extension (additional equipment) is
not permitted!
G
Risk of accidents due to overloading!
The load must always be lifted with the weakest part first (auxiliary single-
sheave boom top).
G
Risk of accidents due to overloading!
The reeving on the main boom must be equal to or greater than that on
the auxiliary single-sheave boom top.
If this condition is not fulfilled, the main hoist cable and main hoisting
gear will become overloaded.
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 5-9
GMK 5100
Auxiliary single-sheave boom top (additional equipment)
5.4 Turning loads with the auxiliary single-sheave boom top
H
Setting SLI For two-hook operation, both hoists must be activated on the SLI.
It is advisable to enter the reevings for both hoists at the start. The values
are stored and called up directly when switching hoisting gears. This eli-
minates the need for input later during operation. Proceed as follows:
Lamp I for the main hoist lights up from the Hoists indicator lamps.
• In the display Reeving , enter the quantity of reeved cable of the main
“" n= hoist cable on the main boom.
Now the reeving for the main hoist is stored and you can switch to the
auxiliary hoist.
• In the display Reeving, enter the quantity of reeved rope on the auxiliary
“! n= hoist rope of the auxiliary single-sheave boom top.
Now the reeving for the auxiliary hoist is also stored and you can switch
16.02.2000
• Switch the main hoist on by pushing up the Main hoist shutdown rocker
ü switch.
• On the display lamps Hoists, lamp II is now lit for the auxiliary hoist and
lamp I is flashing for the main hoist.
• Set the SLI for crane operation with the auxiliary single-sheave boom
# 11=0 top, valid for the current rigging mode of the truck crane.
Now the SLI is set for two-hook operation, taking into account the reeving
H
for the auxiliary hoist and the lifting capacity table for the main boom.
The load measurement is taken using the pressure in the main boom’s
derricking cylinder. The loads detailed in the Lifting capacity table then
lessen with respect to the weight of both reeved hook blocks and the
weight of the auxiliary single-sheave boom top.
Turning a load To turn loads, proceed only in the manner described as follows.
S
Keep the acceleration force as low as possible during two-hook operation.
Therefore move the load at the lowest possible speed!
H As soon as the hoist cable on the main boom is pulled taut, the status dis-
play Actual load will exhibit slight variations. However, the differences are
H
on the safe side with regard to SLI deactivation.
With two-hook operation, the SLI code for the main boom remains acti-
vated during the entire hoist procedure.
16.02.2000
s
Operating instructions for lattice extension 2 084 545 en 5 - 11
GMK 5100
Auxiliary single-sheave boom top (additional equipment)
5.4 Turning loads with the auxiliary single-sheave boom top
C0985
• Lift the load completely off the ground with the auxiliary single-sheave
boom top.
• Only now should you attach the load to the hook block of the main
boom as well.
• Now lift the load with the hook block on the main boom until both sling-
ing points are at the same height.
C0984
16.02.2000
• Reel off hoist cable on the auxiliary single-sheave boom top until the
load is hanging exclusively from the hook block on the main boom.
Turning the load is thus completed.
16.02.2000
E Electrical system
on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . 3 - 55
H Hoist cable
positioning/removing on lattice extension . . . . . . . . . . . . 3 - 52
positioning/removing on the boom extension . . . . . . . . . . 4 - 16
possible reeving methods on the boom extension . . . . . . . . 3 - 54
possible reeving methods on the lattice extension . . . . . . . . 3 - 54
I Identification
auxiliary single-sheave boom top . . . . . . . . . . . . . . 5 - 1 to 5 - 2
of the boom extension . . . . . . . . . . . . . . . . . . . . 4 - 1 to 4 - 2
of the two-stage swing-away lattice extension . . . . . . . 3 - 1 to 3 - 2
important information about these operating instructions . . . . . . . 1-1
16.02.2000
M Malfunctions
boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 80
lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 80
R Reeving methods
on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . 3 - 54
Run-up rail
folding out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32
S SLI
shutdown during work with the boom extension . . . . . . . . 3 - 67
shutdown during work with the lattice extension . . . . . . . . 3 - 67