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Grove GMK 5250XL-1 Crane Lattice Extension Operation Manual PDF Download
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Grove Crane GMK 5250XL-1 Lattice Extension Operating Manual – PDF DOWNLOAD
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Description
Grove Crane GMK 5250XL-1 Lattice Extension Operating Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5250XL-1 Lattice Extension Operating Manual – PDF DOWNLOAD
Language : English
Pages : 526
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5250XL-1 Lattice Extension Operating Manual – PDF DOWNLOAD
Overview:
Validity of this operating manual:
Validity of this operating manual
This operating manual applies only to lattice extensions supplied by Manitowoc Crane Group Germany GmbH.
Prerequisites for installation and operation:
The lattice extensions described in this operating manual may only be operated together with a GROVE truck crane GMK 5250XL-1 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 form: àOperating manual GMK 5250XL-1
• The subject that is referenced can be found in the index or table of contents of the document to which reference is made.
This operating manual applies only to lattice extensions supplied by Manitowoc Crane Group Germany GmbH.
Prerequisites for installation and operation:
The lattice extensions described in this operating manual may only be operated together with a GROVE truck crane GMK 5250XL-1 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 form: àOperating manual GMK 5250XL-1
• The subject that is referenced can be found in the index or table of contents of the document to which reference is made.
Safety instructions for working with a lattice extension:
This chapter contains additional safety instructions only for safe handling of the lattice extensions described in this operating manual.
Working at heights:
- If there is a danger of falling working 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 holders for positioning a ladder. Place the ladder between the holders so that it cannot slip off.
- If despite using such equipment the risk of falling cannot be minimised you must secure yourself and any assisting personnel by using fall arrest systems.
- The points to which the fall arrest system can be attached on the truck crane are indicated by the symbol shown here.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 5250XL-1 Lattice Extension Operating Manual – PDF DOWNLOAD
1 Overview.......................................................................................... 33 Validity of this operating manual............................................................... 33 Validity of this operating manual........................................................... 33 Prerequisites for installation and operation................................................ 33 References to other operating manuals....................................................... 33 Lattice extension described..................................................................... 34 Terms used...................................................................................... 36 Lattice extension parts..................................................................... 36 Additional equipment........................................................................ 37 2 Basic safety instructions......................................................................... 39 Other applicable documents...................................................................... 39 Safety instructions for working with a lattice extension........................................ 40 Working at heights.......................................................................... 40 Slinging.................................................................................... 40 Locks....................................................................................... 40 Rigging mode................................................................................ 40 Two cranes.................................................................................. 40 3 Operating elements................................................................................ 41 On the swing-away lattice....................................................................... 41 In the crane cab................................................................................ 42 Overview.................................................................................... 42 At the control console, right............................................................... 43 On the CCS control unit..................................................................... 43 Menu with independent displays.......................................................... 43 Enter rigging mode/ telescope status menu............................................... 44 Other operating elements........................................................................ 45 On the turntable............................................................................ 45 4 Rigging work on the main boom..................................................................... 47 Hose drum....................................................................................... 47 Slinging points............................................................................. 47 Dimensions and weights...................................................................... 48 Rigging work on the hose drum................................................................... 49 Installing/removing the hose drum........................................................... 49 Removal................................................................................. 51 Engaging/releasing the locking device on the hose drum...................................... 53 Positions of the hydraulic connections...................................................... 54 Working with the lattice extension...................................................... 54 Main boom operation..................................................................... 55 5 Swing-away lattice................................................................................ 57 Swing-away lattice versions..................................................................... 57 Operations planning............................................................................. 59 Permissible combinations.................................................................... 59 Dimensions and weights...................................................................... 60 Identification.............................................................................. 62 Transport conditions............................................................................ 63 Overview.................................................................................... 63 Transport conditions – Notes on checking.................................................... 65 Transport conditions – Folded – Swing-away lattice 17,8 m................................... 67 Transport condition – Folded – Section 1 only............................................... 71 Transport condition – Removed – Swing-away lattice.......................................... 72 Transport condition – Removed – Main boom................................................... 74 Transport condition – Removed – Section 3................................................... 76 Checklists for rigging work..................................................................... 77 Symbols and their representation............................................................ 77 Overview.................................................................................... 78 CHECKLIST: Installation – In the working position........................................... 79 CHECKLIST: Installation – In the transport position......................................... 84 CHECKLIST: Removal – From the working position.............................................. 90 CHECKLIST: Removal – From the transport position – Section 1................................ 95 CHECKLIST: Removal – From the transport position – Swing-away lattice....................... 96 CHECKLIST: Rigging in the working position – 11,2 m......................................... 98 CHECKLIST: Rigging in the working position – 17,8 m.........................................102 CHECKLIST: After rigging in the working position............................................107 CHECKLIST: Before rigging in the transport position.........................................109 CHECKLIST: Rigging in the transport position – 11,2 m.......................................111 CHECKLIST: Rigging in the transport position – 17,8 m.......................................115 Rigging work – General information..............................................................121 Slinging points.............................................................................121 Securing the swing-away lattice with the guide rope.........................................123 Folding the run-up rail out/in..............................................................125 Reeving the guide rope in the run-up rail...................................................126 Section 2 – Folding the deflection sheaves in/out...........................................127 Section 3 – Deflection sheaves – Transport position/ Working position.......................129 Rigging work – Establishing/separating connections..............................................131 Preparing the truck crane...................................................................131 Overview of the rigging ranges..............................................................132 Range 1 – Folded – Slewing connection.......................................................133 Range 1 – Folded down – Main boom/Section 2.................................................134 Range 1 – Folded down – Slewing connection..................................................136 Range 1 – Installing/removing – Main boom/Section 2.........................................137 Range 1 – Installation – Slewing connection.................................................140 Range 2 – Folded – Main boom/Section 2......................................................141 Establishing............................................................................141 Disconnecting...........................................................................142 Range 2 – Folded down/removed – Engage position.............................................143 Range 3 – Installation/Removal – Section 2A/Section 2B......................................144 Establishing............................................................................144 Disconnecting...........................................................................146 Range 3 – Installation/Removal – Section 2/Section 3........................................147 Range 4 – Folded – Main boom/Section 1......................................................150 Range 4 – Installation/Removal – Main boom/Section 1........................................151 Range 5 – Folded – Section 1/Section 2......................................................153 Range 5 – Folded down – Section 1/Section 2.................................................154 Range 6 – Folded – Main boom/Section 1......................................................155 Establishing............................................................................155 Range 6 – Folded – Section 1/Section 2......................................................158 Range 6 – Folded down – Section 1/Section 2.................................................159 Range 6 – Installation/Removal – Section 1/Section 2........................................160 Range 6 – Installation/Removal – Main boom/Section 1........................................162 Relieving the connecting points.............................................................164 Rigging work – Swinging operations..............................................................165 Swing-away lattice – In front of the main boom..............................................165 Swing-away lattice – At the main boom – In range 2..........................................166 Swing-away lattice – At the main boom – In range 6..........................................167 Section 1...................................................................................168 Rigging work – Hydraulic connection.............................................................169 Rigging work – Electrical connections...........................................................171 Overview....................................................................................171 Main boom/Section 2.........................................................................172 Section 1 - Section 2.......................................................................174 Section 2A/Section 2B.......................................................................176 Section 2/Section 3.........................................................................178 Section 3/ Section 2B...................................................................178 Section 2A/ Section 3...................................................................180 Further rigging work............................................................................183 Fitting/removing the hoist rope.............................................................183 Possible reeving methods....................................................................185 Installing/removing the lifting limit switch................................................186 Installation............................................................................186 Removal.................................................................................187 Installing/removing the anemometer and air traffic control light............................188 Installation............................................................................188 Removal.................................................................................189 Installing/removing the camera..............................................................190 Installation............................................................................190 Removal.................................................................................191 Rigging work – Derricking the swing-away lattice................................................193 Display on the derricking cylinder..........................................................193 With the hand-held control..................................................................194 With the control unit on section 2..........................................................195 Operation with swing-away lattice...............................................................197 Setting the RCL.............................................................................197 Input...................................................................................197 Derricking the main boom....................................................................199 Telescoping with a rigged swing-away lattice................................................199 Derricking the swing-away lattice during operation..........................................200 Switching on the derricking gear........................................................200 Raising and lowering....................................................................200 Switching off the derricking gear.......................................................201 Checking the wind speed.....................................................................202 Information on main boom operation when the swing-away lattice is installed.................203 Instructions for turning loads over.........................................................204 Maintenance.....................................................................................205 Maintenance plan W..........................................................................205 M 1 maintenance plan........................................................................205 M 3 maintenance plan........................................................................205 M 12 maintenance plan.......................................................................205 Greasing the piston rod.....................................................................206 Prerequisite............................................................................206 Lubricating the pins........................................................................207 Grease..................................................................................207 Prerequisite............................................................................207 Lubrication.............................................................................207 Checking the sheaves........................................................................208 Grease..................................................................................208 Prerequisite............................................................................208 Check...................................................................................208 Lubricating joints..........................................................................209 Grease..................................................................................209 Lubricating the spring latch on the run-up rail.............................................210 Grease..................................................................................210 Troubleshooting.................................................................................211 Troubleshooting table.......................................................................211 6 Boom extension....................................................................................213 Notes...........................................................................................213 Operations planning.............................................................................215 Permissible combinations....................................................................215 Dimensions and weights......................................................................216 Identification..............................................................................216 Transport conditions............................................................................217 Transport conditions – Notes on checking....................................................217 Transport condition – Removed – Section 4...................................................218 Checklists for rigging work.....................................................................219 Symbols.....................................................................................219 Overview....................................................................................219 CHECKLIST: Installing.......................................................................220 CHECKLIST: Removing.........................................................................225 Rigging work – General information..............................................................229 Slinging points.............................................................................229 Securing with a guide rope..................................................................230 Section 4 – Folding the deflection sheave in/out............................................231 Section 2 – Folding the deflection sheaves in/out...........................................232 Rigging work – Establishing/separating connections..............................................235 Preparing the truck crane...................................................................235 Main boom/section 4.........................................................................236 Section 4/section 2.........................................................................238 Section 2A/Section 2B.......................................................................240 Establishing............................................................................240 Disconnecting...........................................................................242 Rigging work – Hydraulic connection.............................................................243 Main boom/section 4.........................................................................243 Section 4/section 2B........................................................................244 Rigging work – Electrical connections...........................................................245 Main boom/section 4.........................................................................245 Section 4/section 2B........................................................................247 Section 2A/Section 2B.......................................................................249 Further rigging work............................................................................251 Fitting/removing the hoist rope.............................................................251 Operation with boom extension...................................................................253 Setting the RCL.............................................................................253 Input...................................................................................253 Shutdown................................................................................254 Derricking the main boom....................................................................255 Telescoping with a rigged boom extension....................................................255 Derricking the boom extension during operation..............................................256 Checking the wind speed.....................................................................257 Notes on main boom operation................................................................258 Instructions for turning loads over.........................................................258 Maintenance.....................................................................................258 Troubleshooting.................................................................................259 Troubleshooting table.......................................................................259 7 Derricking heavy load lattice extension...........................................................261 Notes...........................................................................................261 Operations planning.............................................................................263 Permissible combination.....................................................................263 Dimensions and weights......................................................................264 Identification..............................................................................265 Transport conditions............................................................................267 Transport conditions – Notes on checking....................................................267 Transport condition – Folded................................................................268 Transport condition – Removed – Section 2B..................................................269 Transport condition – Removed – Section 4...................................................270 Checklists for rigging work.....................................................................271 Symbols.....................................................................................271 Overview....................................................................................271 CHECKLIST: Installation – 3,8 m.............................................................272 CHECKLIST: Installation – 11,8 m............................................................275 CHECKLIST: After installation...............................................................278 CHECKLIST: Before removal...................................................................280 CHECKLIST Removal – 3,8 m...................................................................281 CHECKLIST Removal – 11,8 m..................................................................284 Rigging work – General information..............................................................287 Slinging points.............................................................................287 Securing the heavy load lattice extension with a guide rope.................................288 Folding the deflection sheaves out/in.......................................................289 Folding the head sheave in/out..............................................................291 Rigging work – Establishing / separating connections............................................293 Preparing the truck crane...................................................................293 Main boom / section 2B......................................................................294 Main boom / section 4.......................................................................296 Section 4 / section 2B......................................................................299 Rigging work – Hydraulic connection.............................................................301 Heavy load lattice extension 3,8 m..........................................................301 Heavy load lattice extension 11,8 m.........................................................302 Rigging work – Electrical connections...........................................................305 Heavy load lattice extension 3,8 m..........................................................306 Heavy load lattice extension 11,8 m.........................................................308 Main boom / section 4...................................................................308 Section 4 / section 2B..................................................................310 Further rigging work............................................................................313 Fitting / removing the hoist rope...........................................................313 Removal.................................................................................314 Notes for reeving and unreeving.............................................................315 Possible reeving methods....................................................................316 Installing/removing the lifting limit switch................................................317 Installing/removing the anemometer and air traffic control light............................318 Installing..............................................................................318 Removing................................................................................318 Installing/removing the camera..............................................................319 Rigging work – Derricking the heavy load lattice extension......................................320 Operation with heavy load lattice extension.....................................................321 Setting the RCL.............................................................................321 Input...................................................................................321 Derricking the main boom....................................................................323 Telescoping with a rigged heavy load lattice extension......................................323 Derricking the heavy load lattice extension during operation................................324 Switching on the derricking gear........................................................324 Raising and lowering....................................................................324 Switching off the derricking gear.......................................................325 Checking the wind speed.....................................................................326 Information about main boom operation when the heavy load lattice extension is installed....327 Instructions for turning loads over.........................................................328 Maintenance.....................................................................................329 Maintenance plan W..........................................................................329 M 1 maintenance plan........................................................................329 M 3 maintenance plan........................................................................329 M 12 maintenance plan.......................................................................329 Greasing the piston rod.....................................................................330 Prerequisite............................................................................330 Lubricating the pins........................................................................331 Grease..................................................................................331 Prerequisite............................................................................331 Lubrication.............................................................................331 Checking the sheaves........................................................................332 Prerequisite............................................................................332 Check...................................................................................332 Lubricating joints..........................................................................333 Grease..................................................................................333 Troubleshooting.................................................................................335 Troubleshooting table.......................................................................335 8 Inclinable heavy load lattice extension...........................................................337 Operations planning.............................................................................337 Permissible combination.....................................................................337 Dimensions and weights......................................................................338 Identification..............................................................................339 Transport conditions............................................................................341 Transport conditions – Notes on checking....................................................341 Transport condition – Folded................................................................343 Transport condition – Removed – Section 5...................................................344 Transport condition – Removed – Section 4...................................................345 Checklists for rigging work.....................................................................347 Symbols.....................................................................................347 Overview....................................................................................348 CHECKLIST: Installation – In the working position – 2.0 m...................................349 CHECKLIST: Installation – In the working position – 10.0 m..................................351 CHECKLIST: Installation – In the transport position.........................................353 CHECKLIST: Removal – from the working position – 2.0 m......................................355 CHECKLIST: Removal – from the working position – 10.0 m.....................................357 CHECKLIST: Removal – from transport position................................................359 CHECKLIST: Rigging – in working position....................................................361 CHECKLIST: After rigging in the working position............................................363 CHECKLIST: Before rigging in the transport position.........................................365 CHECKLIST: Rigging – in transport position..................................................367 Rigging work – General information..............................................................369 Slinging points.............................................................................369 Securing the heavy load lattice extension with guide rope...................................370 Section 4 – Folding the deflection sheave in/out............................................371 Rigging work – Establishing / separating connections............................................373 Preparing the truck crane...................................................................373 Installation/removal – Swing connection.....................................................374 Folded down – Swing connection..............................................................375 Folded down – Main boom / section 5.........................................................376 Installation/removal – Main boom / section 5................................................378 Installation/removal – Main boom / section 4................................................380 Installing/removing – section 4 / section 5.................................................382 Rigging work – Swinging the heavy load lattice extension........................................385 Notes on swinging...........................................................................385 Swinging into the transport position........................................................386 Swinging into the working position..........................................................387 Swinging for removal – From the transport position..........................................388 Rigging work – Electrical connections...........................................................389 Heavy load lattice extension 2.0 m..........................................................390 Heavy load lattice extension 10.0 m.........................................................392 Main boom / section 4...................................................................392 Section 4 / Section 5...................................................................394 Further rigging work............................................................................397 Fitting / removing the hoist rope...........................................................397 Removal.................................................................................398 Possible reeving methods....................................................................399 Installing/removing the lifting limit switch................................................400 Installing/removing the anemometer and air traffic control light............................401 Installing..............................................................................401 Removal.................................................................................401 Installing/removing the camera..............................................................402 Inclining the heavy load lattice extension......................................................403 Preparation.................................................................................403 Setting the angle...........................................................................403 After setting the angle.....................................................................405 Operation with heavy load lattice extension.....................................................407 Setting the RCL.............................................................................407 Input...................................................................................407 Shutdown................................................................................408 Derricking the main boom....................................................................409 Telescoping with a rigged heavy load lattice extension......................................409 Checking the wind speed.....................................................................410 Information about main boom operation when the heavy load lattice extension is installed....411 Instructions for turning loads over.........................................................412 Maintenance.....................................................................................413 M 1 maintenance plan........................................................................413 M 3 maintenance plan........................................................................413 Lubricating the pins........................................................................414 Grease..................................................................................414 Prerequisite............................................................................414 Lubrication.............................................................................414 Checking the sheaves........................................................................415 Prerequisite............................................................................415 Check...................................................................................415 Troubleshooting.................................................................................417 Troubleshooting table.......................................................................417 9 Auxiliary single-sheave boom top 1................................................................419 Operations planning.............................................................................419 Permissible combinations....................................................................419 Dimensions and weights......................................................................420 Identification..............................................................................420 Transport conditions............................................................................421 Transport conditions – Instructions for checking............................................421 Transport condition – Folded................................................................423 Transport condition – Removed...............................................................424 Rigging work – General information..............................................................425 Slinging points.............................................................................425 Securing the auxiliary single-sheave boom top with a guide rope.............................426 Rigging work – Installing/removing..............................................................427 In the working position.....................................................................427 Installing..............................................................................427 Removing................................................................................429 In transport position.......................................................................430 Installing..............................................................................430 Removing................................................................................431 Rigging work – Changing the position of the auxiliary single-sheave boom top....................433 From the working position to the transport position.........................................433 From transport position to working position.................................................434 Further rigging work............................................................................437 Fitting/removing the hoist rope.............................................................437 Possible reeving methods....................................................................438 Installing/removing the lifting limit switch................................................439 Installing..............................................................................439 Removing................................................................................440 Installing/removing the anemometer and air traffic control light............................441 Installing/removing the camera..............................................................441 Operation with auxiliary single-sheave boom top.................................................443 Setting the RCL.............................................................................443 Input...................................................................................443 Shutdown................................................................................444 Note on the maximum permissible load........................................................444 Checking the wind speed.....................................................................445 Instructions for turning loads over.........................................................446 Maintenance.....................................................................................447 M 1 maintenance plan........................................................................447 M 3 maintenance plan........................................................................447 Lubricating the pins........................................................................448 Grease..................................................................................448 Prerequisite............................................................................448 Checking the sheaves........................................................................449 Prerequisite............................................................................449 10 Auxiliary single-sheave boom top 2...............................................................451 Operations planning.............................................................................451 Permissible combinations....................................................................451 Dimensions and weights......................................................................452 Identification..............................................................................453 Transport conditions............................................................................455 Transport conditions – Notes on checking....................................................455 Transport condition – Folded................................................................457 Transport condition – Removed...............................................................458 Rigging work – General information..............................................................459 Slinging points.............................................................................459 Securing the auxiliary single-sheave boom top with a guide rope.............................460 Rigging work – Installing/removing..............................................................461 In the working position.....................................................................461 Installing..............................................................................461 Removal.................................................................................463 In the transport position...................................................................464 Installing..............................................................................464 Removal.................................................................................465 Rigging work – Changing the position of the auxiliary single-sheave boom top....................467 From the transport position to the working position.........................................467 From the working position to the transport position.........................................469 Further rigging work............................................................................470 Folding the head sheave in/out..............................................................470 Establishing/disconnecting electrical connections...........................................471 Marker lights...........................................................................471 Lifting limit switch....................................................................472 Fitting/removing the hoist rope.............................................................473 Possible reeving methods....................................................................474 Installing/removing the lifting limit switch................................................475 Installing/removing the anemometer and air traffic control light............................476 Installing/removing the camera..............................................................476 Operation with the auxiliary single-sheave boom top.............................................477 Setting the RCL.............................................................................477 Input...................................................................................477 Shutdown................................................................................478 Note on the maximum permissible load........................................................478 Checking the wind speed.....................................................................479 Instructions for turning loads over.........................................................480 Maintenance.....................................................................................481 M 1 maintenance plan........................................................................481 M 3 maintenance plan........................................................................481 Lubricating the pins........................................................................482 Grease..................................................................................482 Prerequisite............................................................................482 Checking the sheaves........................................................................483 Prerequisite............................................................................483 11 Turning loads over...............................................................................485 Prerequisites...................................................................................485 Setting the RCL.................................................................................486 Entering the reeving........................................................................486 Switching over to the auxiliary hoist.......................................................486 Turning a load over.............................................................................487 12 Driving with a rigged crane......................................................................489 Safety instructions.............................................................................489 Driving distance................................................................................491 Permissible rigging modes and axle loads........................................................492 Notes.......................................................................................492 Notes on the tables.........................................................................492 Swing-away lattice..........................................................................494 Swing-away lattice 11,2 m...............................................................494 Swing-away lattice 17,8 m...............................................................496 Swing-away lattice 25,8 m...............................................................497 Derrickable heavy load lattice extension....................................................498 Heavy load lattice extension 3,8 m......................................................498 Heavy load lattice extension 11,8 m.....................................................500 Inclinable heavy load lattice extension.....................................................502 Heavy load lattice extension 2.0 m......................................................502 Heavy load lattice extension 10.0 m.....................................................504 Boom extension..............................................................................506 Boom extension 19,2 m...................................................................506 Boom extension 25,8 m...................................................................507 Boom extension 33,8 m...................................................................508 Auxiliary single-sheave boom top 1 and auxiliary single-sheave boom top 2...................509 Before driving..................................................................................511 While driving...................................................................................511 After driving...................................................................................511 13 Index............................................................................................513 A...............................................................................................515 B...............................................................................................516 D...............................................................................................517 H...............................................................................................518 I...............................................................................................519 L...............................................................................................520 O...............................................................................................520 R...............................................................................................520 S...............................................................................................520 T...............................................................................................523
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