Grove Crane GMK 5100LSA Lattice Extension Operating Manual 3303108 – PDF DOWNLOAD

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Grove Crane GMK 5100LSA Lattice Extension Operating Manual 3303108 – PDF DOWNLOAD

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Grove Crane GMK 5100LSA Lattice Extension Operating Manual 3303108 – PDF DOWNLOAD

Language : English
Pages : 494
Downloadable : Yes
File Type : PDF

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Grove Crane GMK 5100LSA Lattice Extension Operating Manual 3303108 – PDF DOWNLOAD

Safety instructions for working with a lattice extension:
This chapter contains additional safety instructions only for safe use of the lattice extensions
described in these operating instructions.
Working at heights:

If there is a danger of falling when doing work on the truck crane, suitable equipment must be used
to prevent falling (e. g. ladder, lifting platform, auxiliary crane).

• The lattice extensions are provided with clamps for positioning a ladder. Place the ladder between
  the clamps so it cannot slip off.
• If despite using such equipment the risk of falling cannot be minimised you must protect yourself
  and any assisting personnel by using fall arrest sys- tems.
• The points at which the fall arrest system can be attached to on the truck crane are indicated by
  the symbol shown here.

Slinging:

• Attach slings to the sections only at the designated slinging points. If no slinging points are
  provided, refer to the centre of gravity data.
• In this way you prevent the attached sections slipping off, falling and caus- ing injury during
  installation or removal.

Retainers :

Always secure the pins at the connection points and also at the
holders using the appropriate locks. This prevents unsecured pins coming loose, falling out and
causing injuries.

Rigging mode:

• For crane operation with the lattice extension folded away, comply with
  the rigging mode. This will prevent damage to the main or lattice extension, and prevent the
  lattice extension falling during crane operation.
• For on-road driving with the lattice extension, comply with the rigging mode. This prevents the
  permissible vehicle width or height being
  exceeded.

TABLE OF CONTENTS:

Grove Crane GMK 5100LSA Lattice Extension Operating Manual 3303108 – PDF DOWNLOAD

1 About these operating instructions................................................................................... 31
	1.1 Validity....................................................................................................... 31
	1.2 Terms used..................................................................................................... 32
2 Basic safety instructions............................................................................................ 33
	2.1 Other applicable documents..................................................................................... 33
	2.2 Safety instructions for working with a lattice extension....................................................... 34
3 Operating elements................................................................................................... 35
	3.1 On the lattice extension....................................................................................... 35
		3.1.1 Overview................................................................................................. 35
		3.1.2 Connection section 1 - section 2......................................................................... 36
		3.1.3 Folded connection........................................................................................ 36
		3.1.4 Front connection......................................................................................... 37
		3.1.5 Middle 2 connection...................................................................................... 37
		3.1.6 Middle 1 connection...................................................................................... 38
		3.1.7 Run-up rail.............................................................................................. 38
		3.1.8 Rear connection.......................................................................................... 39
		3.1.9 Section 2 control unit................................................................................... 40
	3.2 In the crane cab............................................................................................... 41
		3.2.1 Overview................................................................................................. 41
		3.2.2 On the CCS control unit.................................................................................. 42
		3.2.3 On the RCL control unit.................................................................................. 43
		3.2.4 At the control console, right............................................................................ 44
	3.3 On the hand-held control....................................................................................... 45
		3.3.1 Hand-held control connection............................................................................. 47
	3.4 Other operating elements....................................................................................... 48
		3.4.1 Rigging hook............................................................................................. 48
4 Rigging work on the main boom........................................................................................ 49
	4.1 Hose drum...................................................................................................... 49
		4.1.1 Slinging points.......................................................................................... 49
		4.1.2 Transport dimensions and weights......................................................................... 50
	4.2 Rigging work on the hose drum.................................................................................. 51
		4.2.1 Fitting/removing the hose drum........................................................................... 51
		4.2.2 Checking the locking device on the hose drum............................................................. 53
		4.2.3 Positions of the hydraulic connections................................................................... 54
5 Swing-away lattice................................................................................................... 59
	5.1 Notes on this chapter.......................................................................................... 59
	5.2 Operations planning............................................................................................ 60
		5.2.1 Assembly................................................................................................. 60
		5.2.2 Identification........................................................................................... 61
		5.2.3 Slinging points.......................................................................................... 62
		5.2.4 Transport dimensions and weights......................................................................... 64
		5.2.5 Transport condition – removed............................................................................ 66
		5.2.6 Transport condition – folded............................................................................. 70
	5.3 Checklists for rigging work.................................................................................... 75
		5.3.1 Overview................................................................................................. 75
		5.3.2 CHECKLIST: Installing the swing-away lattice – into the operating position............................... 77
		5.3.3 CHECKLIST: Installing the swing-away lattice – into the transport position............................... 83
		5.3.4 CHECKLIST: Removing the swing-away lattice – from the operating position................................. 88
		5.3.5 CHECKLIST: Removing the swing-away lattice – from the transport position................................. 94
		5.3.6 CHECKLIST: Rigging the swing-away lattice 1.8 + 9.4 m – in the operating position........................ 98
		5.3.7 CHECKLIST: Rigging the swing-away lattice 1.8 + 16.0 m – in the operating position.......................103
		5.3.8 CHECKLIST: Rigging the swing-away lattice 1.8 + 9.4 m – in the transport position........................108
		5.3.9 CHECKLIST: Rigging the swing-away lattice 1.8 + 16.0 m – in the transport position.......................114
		5.3.10 CHECKLIST: Further rigging work.........................................................................121
	5.4 Rigging work...................................................................................................123
		5.4.1 Notes on the position of the telescoping cylinder........................................................123
		5.4.2 Secure the swing-away lattice with guide rope............................................................124
		5.4.3 Reeving/unreeving the rigging rope.......................................................................125
		5.4.4 Establishing/separating the Rear connection..............................................................126
		5.4.5 Establishing/separating the Middle 1 connection..........................................................127
		5.4.6 Establishing/disconnecting the Front connection..........................................................128
		5.4.7 Folding the run-up rail out/in...........................................................................130
		5.4.8 Establishing/separating the slewing connection...........................................................131
		5.4.9 Establishing/separating the connection between the main boom/section 4...................................133
		5.4.10 Establishing/separating connections between lattice extension sections – during installation/removal....135
		5.4.11 Section 1/section 2 – Establish/separate the right-hand connection......................................141
		5.4.12 Section 1/section 2 – Establish/separate the left-hand connection.......................................142
		5.4.13 Section 1/section 2 – Establishing/separating the Folded connection.....................................144
		5.4.14 Swinging the swing-away lattice.........................................................................145
		5.4.15 Slewing section 1.......................................................................................146
		5.4.16 Establishing/disconnecting the hydraulic connection – Main boom/swing-away lattice......................147
		5.4.17 Establishing/disconnecting electrical connections – swing-away lattice..................................148
		5.4.18 Fold the deflection sheaves in/out on section 2 and section 4...........................................159
		5.4.19 Folding the deflection sheaves on section 3 into the operating position/transport position..............161
		5.4.20 Attaching/removing the hoist rope.......................................................................162
		5.4.21 Installing / removing the lifting limit switch..........................................................164
		5.4.22 Installing / removing the anemometer and air traffic control light......................................166
		5.4.23 Installing / removing the camera........................................................................168
		5.4.24 Derricking cylinder positions...........................................................................170
		5.4.25 Derricking the swing-away lattice for rigging work – hand-held control..................................171
		5.4.26 Derricking the swing-away lattice – Section 2 control unit..............................................172
		5.4.27 Setting the angle – with an auxiliary crane.............................................................173
		5.4.28 Setting the angle – without the auxiliary crane.........................................................174
	5.5 Operation with swing-away lattice..............................................................................181
		5.5.1 Setting the RCL..........................................................................................181
		5.5.2 Derricking the main boom.................................................................................182
		5.5.3 Telescoping with rigged swing-away lattice...............................................................182
		5.5.4 Derricking the swing-away lattice in operation...........................................................183
		5.5.5 Procedure if permissible wind speed is exceeded..........................................................184
		5.5.6 Information about the main boom operation when the swing- away lattice is folded/rigged..................185
		5.5.7 Instructions for turning loads over......................................................................186
	5.6 Maintenance....................................................................................................187
		5.6.5 Description of maintenance work..........................................................................188
	5.7 Finding and eliminating malfunctions...........................................................................194
		5.7.1 Troubleshooting table....................................................................................194
6 Boom extension.......................................................................................................195
	6.1 Notes on this chapter..........................................................................................195
	6.2 Operations planning............................................................................................197
		6.2.1 Assembly.................................................................................................197
		6.2.2 Identification...........................................................................................200
		6.2.3 Slinging points..........................................................................................201
		6.2.4 Transport dimensions and weights.........................................................................202
		6.2.5 Transport condition......................................................................................202
	6.3 Checklists for rigging work....................................................................................203
		6.3.1 Overview.................................................................................................203
		6.3.2 CHECKLIST: Installing the boom extension.................................................................204
		6.3.3 CHECKLIST: Removing the boom extension...................................................................209
	6.4 Description of the rigging work................................................................................215
		6.4.1 Section 5 – Folding out/folding in the deflection sheave.................................................215
		6.4.2 Section 5/main boom – Establish/separate the connection..................................................216
		6.4.3 Section 5/main boom – Establish/separate the electrical connections......................................217
		6.4.4 Section 5/main boom – Establish/separating the hydraulic connection......................................219
		6.4.5 Section 5/section 5 – Establish/separate the connection..................................................220
		6.4.6 Section 5/section 5 – Establish/separate the electrical connections......................................221
		6.4.7 Section 5/section 5 – Establish/separating the hydraulic connection......................................223
		6.4.8 Section 4 – Folding out/folding in the deflection sheave.................................................224
		6.4.9 Section 2 – Folding out/folding in the deflection sheave.................................................225
		6.4.10 Section 4/section 5 – Establishing/separating the connection............................................226
		6.4.11 Section 4/section 5 – Establishing/separating the electrical connections................................227
		6.4.12 Section 4/section 5 – Establishing/separating the hydraulic connection..................................229
		6.4.13 Section 5 – Fitting/removing the hoist rope.............................................................230
	6.5 Operation with boom extension..................................................................................231
		6.5.1 Setting the RCL..........................................................................................231
		6.5.2 Derricking, telescoping the main boom....................................................................232
		6.5.3 Procedure if permissible wind speeds are exceeded........................................................233
		6.5.4 Instructions for turning loads over......................................................................233
	6.6 Maintenance....................................................................................................235
		6.6.3 Description of maintenance work..........................................................................236
7 Integral heavy load lattice extension (ISS) 1.8 + 2.0 m/9.8 + 2.0 m..................................................237
	7.1 Operations planning............................................................................................238
		7.1.1 Assembly.................................................................................................238
		7.1.2 Identification...........................................................................................239
		7.1.3 Slinging points..........................................................................................240
		7.1.4 Transport dimensions and weights.........................................................................241
		7.1.5 Transport condition – removed............................................................................241
		7.1.6 Transport condition – folded.............................................................................243
	7.2 Checklists for rigging work....................................................................................245
		7.2.1 Overview.................................................................................................245
		7.2.2 CHECKLIST: ISS Installing 1.8 + 2.0 m – into the working position........................................246
		7.2.3 CHECKLIST: ISS Removing 1.8 + 2.0 m – from the working position..........................................249
		7.2.4 CHECKLIST: Rigging ISS 1.8 + 2.0 m – into the working position...........................................253
		7.2.5 CHECKLIST: Rigging ISS 1.8 + 2.0 m – into the transport position.........................................257
		7.2.6 CHECKLIST: Rigging ISS 1.8 + 2.0 m from the swing-away lattice – into the working position...............262
		7.2.7 CHECKLIST: Rigging ISS 1.8 + 2.0 m from the swing-away lattice – into the transport position.............266
		7.2.8 CHECKLIST: ISS Installing 9.8 + 2.0 m....................................................................271
		7.2.9 CHECKLIST: ISS Removing 9.8 + 2.0 m......................................................................275
		7.2.10 CHECKLIST: Further rigging work.........................................................................279
	7.3 Rigging work...................................................................................................281
		7.3.1 Securing sections with a guide rope......................................................................281
		7.3.2 Establishing/separating the Middle 2 connection..........................................................282
		7.3.3 Installing/removing section 4............................................................................284
		7.3.4 Establishing/separating connections between section 4 and section 2......................................286
		7.3.5 Connecting/disconnecting the electrical connections – section 4/main boom................................289
		7.3.6 Connecting/disconnecting the hydraulic connections – section 4 / main boom...............................291
		7.3.7 Folding out / folding in the deflection sheave on section 4..............................................292
		7.3.8 Folding out / folding in the head sheave on section 4....................................................293
		7.3.9 Fitting/removing the hoist rope – section 4..............................................................294
		7.3.10 Possible reeving methods on the heavy load lattice extension............................................295
		7.3.11 Connecting/disconnecting the electrical connections – section 4/section 2...............................297
		7.3.12 Installing / removing the lifting limit switch..........................................................299
		7.3.13 Installing / removing the anemometer and air traffic control light......................................300
		7.3.14 Installing / removing the camera........................................................................302
		7.3.15 Folding out / folding in the deflection sheave on section 5.............................................303
		7.3.16 Section 5/main boom – Establish/separate the connection.................................................304
		7.3.17 Connecting/disconnecting the electrical connections – section 5/main boom...............................305
		7.3.18 Connecting/disconnecting the hydraulic connections – section 5 / main boom..............................307
		7.3.19 Installing/removing section 4 on section 5..............................................................308
		7.3.20 Connection/disconnecting the electrical connections between section 4 and section 5.....................309
		7.3.21 Connection/disconnecting the hydraulic connection between section 4 and section 5.......................311
		7.3.22 Positioning/removing the hoist rope – section 5 and section 4...........................................312
		7.3.23 Derricking cylinder positions...........................................................................314
	7.4 ISS, derricking................................................................................................315
	7.5 Operation with the ISS.........................................................................................317
		7.5.1 Setting the RCL..........................................................................................317
		7.5.2 Derricking, telescoping the main boom....................................................................319
		7.5.3 Procedure if permissible wind speeds are exceeded........................................................320
		7.5.4 Instructions for turning loads over......................................................................320
	7.6 Maintenance....................................................................................................321
		7.6.5 Description of maintenance work..........................................................................322
8 Heavy load lattice extension (SLS) 2.0 m/10.0 m......................................................................327
	8.1 Operations planning............................................................................................327
		8.1.1 Assembly.................................................................................................327
		8.1.2 Identification...........................................................................................328
		8.1.3 Slinging points..........................................................................................329
		8.1.4 Transport dimensions and weights.........................................................................330
		8.1.5 Transport condition......................................................................................331
	8.2 Checklists for rigging work....................................................................................333
		8.2.1 Overview.................................................................................................333
		8.2.2 CHECKLIST: SLS Installing 2.0 m – into the working position..............................................334
		8.2.3 CHECKLIST: SLS Installing 2.0 m – into the transport position............................................337
		8.2.4 CHECKLIST: SLS Removing 2.0 m – from the working position................................................338
		8.2.5 CHECKLIST: SLS Removing 2.0 m – from transport position..................................................341
		8.2.6 CHECKLIST: SLS Rigging 2.0 m – into the working position.................................................343
		8.2.7 CHECKLIST: SLS Rigging 2.0 m – into the transport position...............................................346
		8.2.8 CHECKLIST: SLS Installing 10.0 m.........................................................................349
		8.2.9 CHECKLIST: SLS Removing 10.0 m...........................................................................353
	8.3 Description of the rigging work................................................................................357
		8.3.1 Section 6/main boom– Establish/separate the connection in the working position...........................357
		8.3.2 Section 6/main boom – Establish/separate the connection in the transport position........................359
		8.3.3 Bringing section 6 from the transport position into the working position.................................361
		8.3.4 Bringing section 6 into the transport position...........................................................362
		8.3.5 Section 6/main boom – Establish/separate the electrical connections......................................363
		8.3.6 Section 6 – Setting the angle............................................................................365
		8.3.7 Section 6 – Fitting/removing the hoist rope..............................................................366
		8.3.8 Possible reeving methods on the heavy load lattice extension.............................................367
		8.3.9 Installing / removing the lifting limit switch...........................................................369
		8.3.10 Installing / removing the anemometer and air traffic control light......................................370
		8.3.11 Installing / removing the camera........................................................................372
		8.3.12 Section 5 – Folding out/folding in the deflection sheave................................................373
		8.3.13 Section 5/main boom – Establish/separate the connection.................................................374
		8.3.14 Section 5/main boom – Establish/separate the electrical connections.....................................375
		8.3.15 Section 6/section 5 – Establishing/separating the connection............................................377
		8.3.16 Section 6/section 5 – Establishing/separating the electrical connections................................378
		8.3.17 Section 6/section 5 – Fitting/removing the hoist rope...................................................380
	8.4 Operation with the heavy load lattice extension................................................................383
		8.4.1 Setting the RCL..........................................................................................383
		8.4.2 Derricking, telescoping the main boom....................................................................385
		8.4.3 Procedure if permissible wind speeds are exceeded........................................................386
		8.4.4 Instructions for turning loads over......................................................................386
	8.5 Maintenance....................................................................................................387
		8.5.4 Description of maintenance work..........................................................................388
9 Auxiliary single-sheave boom top 1...................................................................................391
	9.1 Operations planning............................................................................................391
		9.1.1 Identification...........................................................................................391
		9.1.2 Slinging points..........................................................................................392
		9.1.3 Transport dimensions and weights.........................................................................393
		9.1.4 Transport condition......................................................................................393
	9.2 Description of the rigging work................................................................................395
		9.2.1 Moving the auxiliary single-sheave boom top into the operating position..................................395
		9.2.2 Moving the auxiliary single-sheave boom top into the transport position..................................397
		9.2.3 Installing/removing a folded up auxiliary single-sheave boom top.........................................399
		9.2.4 Attaching/removing the hoist rope........................................................................400
		9.2.5 Installing / removing the lifting limit switch and anemometer............................................402
	9.3 Operation with the auxiliary single-sheave boom top 1..........................................................405
		9.3.1 Setting the RCL..........................................................................................405
		9.3.2 Procedure if permissible wind speeds are exceeded........................................................406
		9.3.3 Instructions for turning loads over......................................................................406
	9.4 Maintenance....................................................................................................407
		9.4.3 Description of maintenance work..........................................................................408
10 Auxiliary single-sheave boom top 2..................................................................................409
	10.1 Operations planning...........................................................................................409
		10.1.1 Identification..........................................................................................409
		10.1.2 Slinging points.........................................................................................410
		10.1.3 Transport dimensions and weights........................................................................411
		10.1.4 Transport condition.....................................................................................411
	10.2 Description of the rigging work...............................................................................413
		10.2.1 Moving the auxiliary single-sheave boom top into the operating position.................................413
		10.2.2 Moving the auxiliary single-sheave boom top into the transport position.................................415
		10.2.3 Installing/removing a folded up auxiliary single-sheave boom top........................................417
		10.2.4 Connect/disconnect electrical connection for the marker lights..........................................419
		10.2.5 Attaching/removing the hoist rope.......................................................................420
		10.2.6 Installing / removing the lifting limit switch and anemometer...........................................421
	10.3 Operation with the auxiliary single-sheave boom top 2.........................................................423
		10.3.1 Setting the RCL.........................................................................................423
		10.3.2 Procedure if permissible wind speeds are exceeded.......................................................424
		10.3.3 Instructions for turning loads over.....................................................................424
	10.4 Maintenance...................................................................................................425
		10.4.3 Description of maintenance work.........................................................................426
11 Turning loads over..................................................................................................427
	11.1 Setting the RCL...............................................................................................428
	11.2 Turning a load over...........................................................................................429
12 Driving with a rigged crane.........................................................................................431
	12.1 Safety instructions...........................................................................................431
	12.2 Driving path..................................................................................................432
	12.3 Permissible rigging modes and axle loads – GMK5150............................................................433
		12.3.1 Swing-away lattice......................................................................................434
		12.3.2 Boom extension..........................................................................................440
		12.3.3 Integral heavy load lattice extension...................................................................450
		12.3.4 Heavy load lattice extension 2.0 m/10 m.................................................................454
		12.3.5 Auxiliary single-sheave boom top 1 and auxiliary single-sheave boom top 2...............................458
	12.4 Permissible rigging modes and axle loads – GMK5100LSA.........................................................459
		12.4.1 Swing-away lattice......................................................................................460
		12.4.2 Boom extension..........................................................................................466
		12.4.3 Integral heavy load lattice extension...................................................................472
		12.4.4 Heavy load lattice extension 2.0 m/10 m.................................................................476
		12.4.5 Auxiliary single-sheave boom top 1 and auxiliary single-sheave boom top 2...............................480
	12.5 Before driving................................................................................................481
	12.6 While driving.................................................................................................481
	12.7 After driving.................................................................................................481
13 Index...............................................................................................................483
	A..................................................................................................................485
	B..................................................................................................................485
	D..................................................................................................................486
	H..................................................................................................................487
	I..................................................................................................................488
	L..................................................................................................................489
	M..................................................................................................................489
	O..................................................................................................................489
	P..................................................................................................................489
	R..................................................................................................................489
	S..................................................................................................................490
	T..................................................................................................................491

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