Grove Crane GMK 5150 GMK 5150L Lattice Extension Operating Manual 3302624 – PDF DOWNLOAD

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Grove Crane GMK 5150 GMK 5150L Lattice Extension Operating Manual 3302624 – PDF DOWNLOAD

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Grove Crane GMK 5150 GMK 5150L Lattice Extension Operating Manual 3302624 – PDF DOWNLOAD

Language : English
Pages : 494
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File Type : PDF

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Grove Crane GMK 5150 GMK 5150L Lattice Extension Operating Manual 3302624 – PDF DOWNLOAD

About these operating instructions
1.1 Validity

Validity of these operating instructions:

• This operating manual applies only to lattice extensions supplied by
  Manitowoc Crane Group Germany GmbH.
• In addition, for the operation of the truck crane with a lattice extension described in these
  operating instructions, all information in the Operating Instructions GMK5150 / GMK5150L, supplied
  by the factory for the lattice extensions is applicable.

Prerequisites for installation and operation:

The lattice extensions described in this operating manual may only be oper- ated together with a
GROVE truck crane GMK5150 / GMK5150L whose serial number is identical with the serial number marked
on the lattice extensions.

References to other operating manuals:

• Cross references to other operating or maintenance manuals are shown for instance in the following
  form: à GMK5150 / GMK5150L Operating Instructions.
• The subject that is referenced can be found in the index or table of contents
  of the document to which reference is made.

TABLE OF CONTENTS:

Grove Crane GMK 5150 GMK 5150L Lattice Extension Operating Manual 3302624 – PDF DOWNLOAD

1 About these operating instructions............................................................................  7
	1.1 Validity................................................................................................  7
	1.2 Terms used..............................................................................................  8
2 Basic safety instructions..................................................................................... 11
	2.1 Other applicable documents.............................................................................. 11
	2.2 Safety instructions for working with a lattice extension................................................ 12
3 Operating elements............................................................................................ 15
	3.1 On the lattice extension................................................................................ 15
		3.1.1 Overview.......................................................................................... 15
		3.1.2 Connection section 1 - section 2.................................................................. 16
		3.1.3 Folded connection................................................................................. 16
		3.1.4 Front connection.................................................................................. 17
		3.1.5 Middle 2 connection............................................................................... 17
		3.1.6 Middle 1 connection............................................................................... 18
		3.1.7 Run-up rail....................................................................................... 18
		3.1.8 Rear connection................................................................................... 19
		3.1.9 Section2 control unit............................................................................ 20
	3.2 In the crane cab........................................................................................ 21
		3.2.1 Overview.......................................................................................... 21
		3.2.2 On the CCS control unit........................................................................... 22
		3.2.3 On the RCL control unit........................................................................... 23
		3.2.4 At the control console, right..................................................................... 24
	3.3 On the hand-held control................................................................................ 25
		3.3.1 Hand-held control connection...................................................................... 27
	3.4 Other operating elements................................................................................ 28
		3.4.1 Rigging hook...................................................................................... 28
4 Rigging work on the main boom................................................................................. 31
	4.1 Hose drum............................................................................................... 31
		4.1.1 Slinging points................................................................................... 31
		4.1.2 Transport dimensions and weights.................................................................. 32
	4.2 Rigging work on the hose drum........................................................................... 33
		4.2.1 Fitting/removing the hose drum.................................................................... 33
		4.2.2 Checking the locking device on the hose drum...................................................... 35
		4.2.3 Positions of the hydraulic connections.......................................................... 36
5 Swing-away lattice............................................................................................ 43
	5.1 Notes on this chapter................................................................................... 43
	5.2 Operations planning..................................................................................... 44
		5.2.1 Assembly.......................................................................................... 44
		5.2.2 Identification.................................................................................... 45
		5.2.3 Slinging points................................................................................... 46
		5.2.4 Transport dimensions and weights.................................................................. 48
		5.2.5 Transport condition – removed..................................................................... 50
		5.2.6 Transport condition – folded...................................................................... 54
	5.3 Checklists for rigging work............................................................................. 59
		5.3.1 Overview.......................................................................................... 59
		5.3.2 CHECKLIST: Installing the swing-away lattice – into the operating position........................ 61
		5.3.3 CHECKLIST: Installing the swing-away lattice – into the transport position........................ 67
		5.3.4 CHECKLIST: Removing the swing-away lattice – from the operating position.......................... 72
		5.3.5 CHECKLIST: Removing the swing-away lattice – from the transport position.......................... 78
		5.3.6 CHECKLIST: Rigging the swing-away lattice 1.8 + 9.4 m – in the operating position................. 82
		5.3.7 CHECKLIST: Rigging the swing-away lattice 1.8 + 16.0 m – in the operating position................ 87
		5.3.8 CHECKLIST: Rigging the swing-away lattice 1.8 + 9.4 m – in the transport position................. 92
		5.3.9 CHECKLIST: Rigging the swing-away lattice 1.8 + 16.0 m – in the transport position................ 98
		5.3.10 CHECKLIST: Further rigging work..................................................................105
	5.4 Rigging work............................................................................................107
		5.4.1 Notes on the position of the telescoping cylinder.................................................107
		5.4.2 Secure the swing-away lattice with guide rope.....................................................108
		5.4.3 Reeving/unreeving the rigging rope................................................................109
		5.4.4 Establishing/separating the Rear connection.......................................................110
		5.4.5 Establishing/separating the Middle1 connection...................................................111
		5.4.6 Establishing/disconnecting the Front connection...................................................112
		5.4.7 Folding the run-up rail out/in....................................................................114
		5.4.8 Establishing/separating the slewing connection....................................................115
		5.4.9 Establishing/separating the connection between the main boom/section4............................117
		5.4.10 Establishing/separating connections between lattice extension sections – during installati.......119
		5.4.11 Section1/section2 – Establish/separate the right-hand connection...............................125
		5.4.12 Section1/section2 – Establish/separate the left-hand connection................................126
		5.4.13 Section1/section2 – Establishing/separating the Folded connection..............................128
		5.4.14 Swinging the swing-away lattice..................................................................129
		5.4.15 Slewing section1................................................................................130
		5.4.16 Establishing/disconnecting the hydraulic connection – Main boom/swing-away lattice...............131
		5.4.17 Establishing/disconnecting electrical connections – swingaway lattice...........................132
		5.4.18 Fold the deflection sheaves in/out on section2 and section4....................................143
		5.4.19 Folding the deflection sheaves on section3 into the operating position/transport position.......145
		5.4.20 Attaching/removing the hoist rope................................................................146
		5.4.21 Installing / removing the lifting limit switch...................................................148
		5.4.22 Installing / removing the anemometer and air traffic control light...............................150
		5.4.23 Installing / removing the camera.................................................................152
		5.4.24 Derricking cylinder positions....................................................................154
		5.4.25 Derricking the swing-away lattice for rigging work – hand-held control...........................155
		5.4.26 Derricking the swing-away lattice – Section2 control unit.......................................156
		5.4.27 Setting the angle – with an auxiliary crane......................................................157
		5.4.28 Setting the angle – without the auxiliary crane.................................................158
	5.5 Operation with swing-away lattice.......................................................................165
		5.5.1 Setting the RCL...................................................................................165
		5.5.2 Derricking the main boom..........................................................................166
		5.5.3 Telescoping with rigged swing-away lattice........................................................166
		5.5.4 Derricking the swing-away lattice in operation....................................................167
		5.5.5 Procedure if permissible wind speed is exceeded...................................................168
		5.5.6 Information about the main boom operation when the swing- away lattice is folded/rigged...........169
		5.5.7 Instructions for turning loads over...............................................................170
	5.6 Maintenance.............................................................................................171
		5.6.5 Description of maintenance work...................................................................172
	5.7 Finding and eliminating malfunctions....................................................................178
		5.7.1 Troubleshooting table.............................................................................178
6 Boom extension................................................................................................181
	6.1 Notes on this chapter...................................................................................181
	6.2 Operations planning.....................................................................................183
		6.2.1 Assembly..........................................................................................183
		6.2.2 Identification....................................................................................186
		6.2.3 Slinging points...................................................................................187
		6.2.4 Transport dimensions and weights..................................................................188
		6.2.5 Transport condition...............................................................................188
	6.3 Checklists for rigging work.............................................................................189
		6.3.1 Overview..........................................................................................189
		6.3.2 CHECKLIST: Installing the boom extension..........................................................190
		6.3.3 CHECKLIST: Removing the boom extension............................................................195
	6.4 Description of the rigging work.........................................................................201
		6.4.1 Section5 – Folding out/folding in the deflection sheave..........................................201
		6.4.2 Section5/main boom – Establish/separate the connection...........................................202
		6.4.3 Section5/main boom – Establish/separate the electrical connections...............................203
		6.4.4 Section5/main boom – Establish/separating the hydraulic connection...............................205
		6.4.5 Section5/section5 – Establish/separate the connection...........................................206
		6.4.6 Section5/section5 – Establish/separate the electrical connections...............................207
		6.4.7 Section5/section5 – Establish/separating the hydraulic connection...............................209
		6.4.8 Section4 – Folding out/folding in the deflection sheave..........................................210
		6.4.9 Section2 – Folding out/folding in the deflection sheave..........................................211
		6.4.10 Section4/section5 – Establishing/separating the connection.....................................212
		6.4.11 Section4/section5 – Establishing/separating the electrical connections.........................213
		6.4.12 Section4/section5 – Establishing/separating the hydraulic connection...........................215
		6.4.13 Section5 – Fitting/removing the hoist rope......................................................216
	6.5 Operation with boom extension...........................................................................217
		6.5.1 Setting the RCL...................................................................................217
		6.5.2 Derricking, telescoping the main boom.............................................................218
		6.5.3 Procedure if permissible wind speeds are exceeded.................................................219
		6.5.4 Instructions for turning loads over...............................................................219
	6.6 Maintenance.............................................................................................221
		6.6.3 Description of maintenance work...................................................................222
7 Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m...........................................225
	7.1 Operations planning.....................................................................................226
		7.1.1 Assembly..........................................................................................226
		7.1.2 Identification....................................................................................227
		7.1.3 Slinging points...................................................................................228
		7.1.4 Transport dimensions and weights..................................................................229
		7.1.5 Transport condition – removed.....................................................................229
		7.1.6 Transport condition – folded......................................................................231
	7.2 Checklists for rigging work.............................................................................233
		7.2.1 Overview..........................................................................................233
		7.2.2 CHECKLIST: ISS Installing 1.8 + 2.0m – into the working position.................................234
		7.2.3 CHECKLIST: ISS Removing 1.8 + 2.0m – from the working position...................................237
		7.2.4 CHECKLIST: Rigging ISS 1.8 + 2.0m – into the working position....................................241
		7.2.5 CHECKLIST: Rigging ISS 1.8 + 2.0m – into the transport position..................................245
		7.2.6 CHECKLIST: Rigging ISS 1.8 + 2.0m from the swing-away lattice – into the working position........250
		7.2.7 CHECKLIST: Rigging ISS 1.8 + 2.0m from the swing-away lattice – into the transport position......254
		7.2.8 CHECKLIST: ISS Installing 9.8 + 2.0m.............................................................259
		7.2.9 CHECKLIST: ISS Removing 9.8 + 2.0m...............................................................263
		7.2.10 CHECKLIST: Further rigging work..................................................................267
	7.3 Rigging work............................................................................................269
		7.3.1 Securing sections with a guide rope...............................................................269
		7.3.2 Establishing/separating the Middle 2 connection...................................................270
		7.3.3 Installing/removing section4.....................................................................272
		7.3.4 Establishing/separating connections between section4 and section2...............................274
		7.3.5 Connecting/disconnecting the electrical connections – section4/main boom.........................277
		7.3.6 Connecting/disconnecting the hydraulic connections – section4 / main boom........................279
		7.3.7 Folding out / folding in the deflection sheave on section4.......................................280
		7.3.8 Folding out / folding in the head sheave on section4.............................................281
		7.3.9 Fitting/removing the hoist rope – section4.......................................................282
		7.3.10 Possible reeving methods on the heavy load lattice extension.....................................283
		7.3.11 Connecting/disconnecting the electrical connections – section4/section2........................285
		7.3.12 Installing / removing the lifting limit switch...................................................287
		7.3.13 Installing / removing the anemometer and air traffic control light...............................288
		7.3.14 Installing / removing the camera.................................................................290
		7.3.15 Folding out / folding in the deflection sheave on section5......................................291
		7.3.16 Section5/main boom – Establish/separate the connection..........................................292
		7.3.17 Connecting/disconnecting the electrical connections – section5/main boom........................293
		7.3.18 Connecting/disconnecting the hydraulic connections – section5 / main boom.......................295
		7.3.19 Installing/removing section4 on section5.......................................................296
		7.3.20 Connection/disconnecting the electrical connections between section4 and section5..............297
		7.3.21 Connection/disconnecting the hydraulic connection between section4 and section5................299
		7.3.22 Positioning/removing the hoist rope – section5 and section4....................................300
		7.3.23 Derricking cylinder positions....................................................................302
	7.4 ISS, derricking.........................................................................................303
	7.5 Operation with the ISS..................................................................................305
		7.5.1 Setting the RCL...................................................................................305
		7.5.2 Derricking, telescoping the main boom.............................................................307
		7.5.3 Procedure if permissible wind speeds are exceeded.................................................308
		7.5.4 Instructions for turning loads over...............................................................308
	7.6 Maintenance.............................................................................................309
		7.6.5 Description of maintenance work...................................................................310
8 Heavy load lattice extension (SLS) 2.0m/10.0m...............................................................317
	8.1 Operations planning.....................................................................................317
		8.1.1 Assembly..........................................................................................317
		8.1.2 Identification....................................................................................318
		8.1.3 Slinging points...................................................................................319
		8.1.4 Transport dimensions and weights..................................................................320
		8.1.5 Transport condition...............................................................................321
	8.2 Checklists for rigging work.............................................................................323
		8.2.1 Overview..........................................................................................323
		8.2.2 CHECKLIST: SLS Installing 2.0m – into the working position.......................................324
		8.2.3 CHECKLIST: SLS Installing 2.0m – into the transport position.....................................327
		8.2.4 CHECKLIST: SLS Removing 2.0m – from the working position.........................................328
		8.2.5 CHECKLIST: SLS Removing 2.0m – from transport position...........................................331
		8.2.6 CHECKLIST: SLS Rigging 2.0m – into the working position..........................................333
		8.2.7 CHECKLIST: SLS Rigging 2.0m – into the transport position........................................336
		8.2.8 CHECKLIST: SLS Installing 10.0m..................................................................339
		8.2.9 CHECKLIST: SLS Removing 10.0m....................................................................343
	8.3 Description of the rigging work.........................................................................347
		8.3.1 Section6/main boom– Establish/separate the connection in the working position....................347
		8.3.2 Section6/main boom – Establish/separate the connection in the transport position.................349
		8.3.3 Bringing section6 from the transport position into the working position..........................351
		8.3.4 Bringing section6 into the transport position....................................................352
		8.3.5 Section6/main boom – Establish/separate the electrical connections...............................353
		8.3.6 Section6 – Setting the angle.....................................................................355
		8.3.7 Section6 – Fitting/removing the hoist rope.......................................................356
		8.3.8 Possible reeving methods on the heavy load lattice extension......................................357
		8.3.9 Installing / removing the lifting limit switch....................................................359
		8.3.10 Installing / removing the anemometer and air traffic control light...............................360
		8.3.11 Installing / removing the camera.................................................................362
		8.3.12 Section5 – Folding out/folding in the deflection sheave.........................................363
		8.3.13 Section5/main boom – Establish/separate the connection..........................................364
		8.3.14 Section5/main boom – Establish/separate the electrical connections..............................365
		8.3.15 Section6/section5 – Establishing/separating the connection.....................................367
		8.3.16 Section6/section5 – Establishing/separating the electrical connections.........................368
		8.3.17 Section6/section5 – Fitting/removing the hoist rope............................................370
	8.4 Operation with the heavy load lattice extension.........................................................373
		8.4.1 Setting the RCL...................................................................................373
		8.4.2 Derricking, telescoping the main boom.............................................................375
		8.4.3 Procedure if permissible wind speeds are exceeded.................................................376
		8.4.4 Instructions for turning loads over...............................................................376
	8.5 Maintenance.............................................................................................377
		8.5.4 Description of maintenance work...................................................................378
9 Auxiliary single-sheave boom top1............................................................................383
	9.1 Operations planning.....................................................................................383
		9.1.1 Identification....................................................................................383
		9.1.2 Slinging points...................................................................................384
		9.1.3 Transport dimensions and weights..................................................................385
		9.1.4 Transport condition...............................................................................385
	9.2 Description of the rigging work.........................................................................387
		9.2.1 Moving the auxiliary single-sheave boom top into the operating position...........................387
		9.2.2 Moving the auxiliary single-sheave boom top into the transport position...........................389
		9.2.3 Installing/removing a folded up auxiliary single-sheave boomtop..................................391
		9.2.4 Attaching/removing the hoist rope.................................................................392
		9.2.5 Installing / removing the lifting limit switch and anemometer.....................................394
	9.3 Operation with the auxiliary single-sheave boom top1...................................................397
		9.3.1 Setting the RCL...................................................................................397
		9.3.2 Procedure if permissible wind speeds are exceeded.................................................398
		9.3.3 Instructions for turning loads over...............................................................398
	9.4 Maintenance.............................................................................................399
		9.4.3 Description of maintenance work...................................................................400
10 Auxiliary single-sheave boom top2...........................................................................403
	10.1 Operations planning....................................................................................403
		10.1.1 Identification...................................................................................403
		10.1.2 Slinging points..................................................................................404
		10.1.3 Transport dimensions and weights.................................................................405
		10.1.4 Transport condition..............................................................................405
	10.2 Description of the rigging work........................................................................407
		10.2.1 Moving the auxiliary single-sheave boom top into the operating position..........................407
		10.2.2 Moving the auxiliary single-sheave boom top into the transport position..........................409
		10.2.3 Installing/removing a folded up auxiliary single-sheave boom top.................................411
		10.2.4 Connect/disconnect electrical connection for the marker lights...................................413
		10.2.5 Attaching/removing the hoist rope................................................................414
		10.2.6 Installing / removing the lifting limit switch and anemometer....................................415
	10.3 Operation with the auxiliary single-sheave boom top2..................................................417
		10.3.1 Setting the RCL..................................................................................417
		10.3.2 Procedure if permissible wind speeds are exceeded................................................418
		10.3.3 Instructions for turning loads over..............................................................418
	10.4 Maintenance............................................................................................419
		10.4.3 Description of maintenance work..................................................................420
11 Turning loads over...........................................................................................423
	11.1 Setting the RCL........................................................................................424
	11.2 Turning a load over....................................................................................425
12 Driving with a rigged crane..................................................................................429
	12.1 Safety instructions....................................................................................429
	12.2 Driving path...........................................................................................430
	12.3 Permissible rigging modes and axle loads – GMK5150.....................................................431
		12.3.1 Swing-away lattice...............................................................................432
		12.3.2 Boom extension...................................................................................438
		12.3.3 Integral heavy load lattice extension............................................................448
		12.3.4 Heavy load lattice extension 2.0m/10m..........................................................452
		12.3.5 Auxiliary single-sheave boom top 1 and auxiliary single-sheave boom top 2........................456
	12.4 Permissible rigging modes and axle loads – GMK5150L....................................................457
		12.4.1 Swing-away lattice...............................................................................458
		12.4.2 Boom extension...................................................................................464
		12.4.3 Integral heavy load lattice extension............................................................470
		12.4.4 Heavy load lattice extension 2.0m/10m..........................................................474
		12.4.5 Auxiliary single-sheave boom top 1 and auxiliary single-sheave boom top 2........................478
	12.5 Before driving.........................................................................................479
	12.6 While driving..........................................................................................479
	12.7 After driving..........................................................................................479
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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