Grove GMK 5220 Operating Instructions Lattice Extension Manual – PDF DOWNLOAD

Description

Grove GMK 5220 Operating Instructions Lattice Extension Manual – PDF DOWNLOAD

DESCRIPTION:

Grove GMK 5220 Operating Instructions Lattice Extension Manual – PDF DOWNLOAD

Serial number 3 112 239 en

Intended use:

• The GMK 5220 truck crane is constructed in accordance with the latest technology and the recognized safety regulations. Nevertheless, personal injury to the operator or a third party as well as damage to the crane and other property may occur during use.
• The truck crane may only be modified with the consent of the manufacturer.
• The GMK 5220 truck crane may only be used when in excellent working condition and for its intended purpose, and with due attention to safe operation and any possible hazards. Malfunctions that may affect safe operation are to be corrected immediately.
• The GMK 5220 truck crane may only be operated at temperatures of between –25°C and +40°C (between –13°F and +104°F) if unless equipped with the relevant special equipment.
• The GMK 5220 truck crane may only be used to vertically lift loads in the authorized rigging modes using a hook block that is reeved to the hoist rope. The weight and centre of distribution of the loads must be known. Any other use of the crane is not considered to represent intended use.
• The manufacturer is not liable for damage resulting from the improper or unauthorized use of the truck crane GMK 5220. The user shall take full responsibility for any such use.

Intended use also entails the following:
– Observing the complete crane documentation consisting of the operating
instructions, the lifting capacity table, the outrigger pressure table and the
safety manual
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual.

Improper use includes:
– Transporting loads on the carrier
– Pushing, pulling or lifting loads with the level adjustment system, the
beams or the outrigger cylinders
– Pushing, pulling or lifting loads off the ground using the slewing gear, the
derricking gear or the telescoping mechanism
– Pulling off fixed objects using the crane
– Two-hook operation with the boom extension and two-hook operation on
the main boom head without additional equipment
– Defining SLI codes that do not correspond to the actual rigging mode
– Working with an overridden SLI or overridden lifting limit switch
– After SLI deactivation, increasing the radius by pulling the raised load at
an angle (e.g. with a chain hoist)
– Misuse of the outrigger pressure indicator (additional equipment) as a
safety function to prevent overturning after an SLI shutdown (outrigger
pressure greater than 0 t)
– Road driving in an unauthorized driving mode (axle load, dimension)
– Moving the rigged crane in an unauthorized driving mode
– Use of equipment that is not authorized for use with the crane
– Transporting people in any way with the lifting tackle, upon the load, or in
the crane cab while driving
– Carrying passengers outside the driver’s cab
– Loading and unloading work, i.e. continuous operation without a sufficiently
long break
– Usage for any kind of sport or recreation event, especially for bungee
jumping

TABLE OF CONTENTS:

Grove GMK 5220 Operating Instructions Lattice Extension Manual – PDF DOWNLOAD

1 Important information.........................................................................................  7
	1.1 About these operating instructions......................................................................  7
		Validity of these operating instructions................................................................  7
		Prerequisites for assembly and operation................................................................  7
		Safetyinstructions.....................................................................................  7
		References to other operating instructions..............................................................  7
	1.2 Basic safety instructions...............................................................................  8
		1.2.1 Warnings and symbols..............................................................................  8
	1.3 Intended use............................................................................................  9
	1.4 Organizational measures................................................................................. 11
	1.5 Personnel qualifications................................................................................ 13
	1.6 Safety instructions for truck crane work................................................................ 14
	1.7 Specifications in US standard units of measurement...................................................... 16
2 Transport dimensions and weights.............................................................................. 19
	2.1 Swing-away lattice extension............................................................................ 19
	2.2 Auxiliary single-sheave boom top........................................................................ 20
	2.3 Heavy load lattice extension............................................................................ 20
3 12/21 m (39/69 ft) swing-away lattice extension............................................................... 23
	3.1 Additional operating and display elements............................................................... 23
		3.1.1 In the crane cab.................................................................................. 23
			At the control console, right...................................................................... 23
			On the crane control display....................................................................... 25
			On the safe load indicator.......................................................................... 25
		3.1.2 Operating and display elements on the hand-held control........................................... 27
		3.1.3 Operating and display instruments on the swing-away lattice extension............................. 28
	3.2 Identification of the swing-away lattice extension...................................................... 29
		Serial number onsection1.............................................................................. 30
		Serial number onsection2.............................................................................. 30
	3.3 Composition of the swing-away lattice extension......................................................... 31
	3.4 Centres of gravity for slinging......................................................................... 32
	3.5 Checklists for rigging work............................................................................. 33
		3.5.1 Overview of the required rigging work............................................................. 33
		3.5.2 CHECKLIST: Installing the 12/21 m (39/69 ft) swing-away latticeextension......................... 34
		3.5.3 CHECKLIST: Removing the 12/21 m (39/69 ft) swing-away lattice extension.......................... 36
			For a rigged lattice extension...................................................................... 36
			For a folded lattice extension...................................................................... 38
		3.5.4 CHECKLIST: Rigging the 12/21 m (39/69 ft) swing-away lattice extension............................ 41
		3.5.5 CHECKLIST: Unrigging the 12/21 m(39/69 ft) swing-away lattice extension......................... 47
	3.6 Description of rigging work............................................................................. 53
		3.6.1 Preparing the truck crane for rigging............................................................. 53
			Prerequisites forrigging........................................................................... 53
			Prerequisites forunrigging......................................................................... 53
			Securing the lattice extension with rope............................................................ 54
		3.6.2 Checking the transport condition.................................................................. 55
			Transport condition with lattice extension folded at the side....................................... 56
			Transport condition with removed lattice extension.................................................. 59
		3.6.3 Checking the locking device on the hose drum...................................................... 60
			Undoing the locking device......................................................................... 60
			Inserting the locking device....................................................................... 61
			Position of the hydraulic connections............................................................... 61
		3.6.4 Installing/removing the hose drum................................................................. 63
			Installing the hose drum............................................................................ 63
			Removing the hose drum.............................................................................. 64
		3.6.5 Establishing/disconnecting the hydraulic connection............................................... 65
		3.6.6 Folding the run-up rail out/in.................................................................... 67
		3.6.7 Connections with folded lattice extension......................................................... 68
			Connections in thefront area....................................................................... 68
			Connections in the middle area...................................................................... 73
			Connections in therear area........................................................................ 75
		3.6.8 Connecting/disconnecting the slewing connection................................................... 80
			Creating a slewing connection....................................................................... 80
			Releasing a slewing connection...................................................................... 81
		3.6.9 Connections on the left and right of the main boom head........................................... 82
			Establishing connections........................................................................... 82
			Releasing connections.............................................................................. 83
			Relieving the connecting points.................................................................... 85
		3.6.10 Swinging the lattice extension onto the main boom head........................................... 86
			Prerequisites....................................................................................... 86
			Swinging the lattice extension...................................................................... 86
		3.6.11 Swinging the lattice extension when rigging...................................................... 87
			When rigging – section1............................................................................ 87
			When unrigging – section1.......................................................................... 88
			When rigging – section2............................................................................ 89
			When unrigging – section2.......................................................................... 90
		3.6.12 Establishing/releasing connections on the lattice extension..................................... 91
			Section1 and section2 installed................................................................... 92
			Only section1 installed........................................................................... 94
		3.6.13 Electrical connections on the lattice extension.................................................. 96
			On 12 m (39 ft) swing-away lattice extension........................................................ 96
			On 21 m (69 ft)- swing-away lattice extension....................................................... 98
		3.6.14 Folding deflection sheave out/in................................................................. 99
			Folding out the deflection sheaves................................................................. 99
			Folding in the deflection sheaves..................................................................101
		3.6.15 Positioning/removing the hoist rope..............................................................102
			Positioning the hoist rope.........................................................................102
			Removing the hoist rope............................................................................102
			Possible reeving methods on the lattice extension..................................................103
		3.6.16 Installing/removing the lifting limit switch.....................................................104
			Overriding connection on main boom.................................................................104
			On 12 m (39 ft) swing-away lattice extension........................................................105
			On 21 m (69 ft) swing-away lattice extension........................................................106
		3.6.17 Installing/removing the anemometer...............................................................107
			On 12 m (39 ft) swing-away lattice extension........................................................107
			On 21 m (69 ft) swing-away lattice extension.......................................................109
		3.6.18 Air traffic control light – electrical connection................................................111
			Establishing theelectrical connection.............................................................111
			Switching on/off....................................................................................111
			Disconnecting the electrical connection.............................................................112
		3.6.19 Derricking the lattice extension.................................................................113
			When rigging........................................................................................113
			During operation....................................................................................115
		3.6.20 Transportation on a separate vehicle.............................................................116
	3.7 Operation with the lattice extension....................................................................117
		3.7.1 Setting...........................................................................................118
		3.7.2 Raising and setting down the main boom............................................................120
			Raising.............................................................................................120
			Setting down........................................................................................120
		3.7.3 Telescoping with rigged lattice extension.........................................................121
		3.7.4 Information about the SLI shutdown................................................................122
		3.7.5 Procedure if the permissible wind speed is exceeded...............................................123
		3.7.6 Information about the main boom operation when the lattice extension is folded/rigged.............124
			Folded..............................................................................................124
			Rigged..............................................................................................124
	3.8 Turning loads with the lattice extension................................................................127
		3.8.1 Prerequisites.....................................................................................127
		3.8.2 Setting the SLI...................................................................................128
			Entering a reeving..................................................................................128
			Setting the SLI to the auxiliary hoist..............................................................129
		3.8.3 Turning a load....................................................................................130
	3.9 Driving with rigged truck crane and rigged lattice extension............................................133
		3.9.1 Driving route.....................................................................................134
		3.9.2 Boom positions and axle loads.....................................................................135
			Notes on the tables.................................................................................135
			12 m (39 ft) swing- awaylattice extension..........................................................136
			21 m (69 ft) swing- awaylattice extension.........................................................137
		3.9.3 Driving the rigged crane..........................................................................138
			Closing the slewing gear brake......................................................................138
			Retracting the outriggers..........................................................................138
			Switching over suspension...........................................................................139
			Switching on separate steering......................................................................140
			Driving.............................................................................................140
			Levelling the free- standing truck crane............................................................141
			Supporting the truck crane.........................................................................142
	3.10 Finding and eliminating malfunctions...................................................................143
	3.11 Maintenance work.......................................................................................145
		3.11.1 Modules in need of protection during cleaning work...............................................145
		3.11.2 Maintenance work M1, monthly.....................................................................146
			Pins................................................................................................146
		3.11.3 Maintenance work M12, every twelve months........................................................147
			Lubricate joints on section1.......................................................................147
4 Boom extension................................................................................................151
	4.1 Identification and slinging points......................................................................151
		4.1.1 Identification....................................................................................151
		4.1.2 Slinging points...................................................................................152
	4.2 Assembly of boom extensions.............................................................................153
	4.3 Checklists for rigging work.............................................................................155
		4.3.1 CHECKLIST: Rigging the 29/37 m (95/121 ft) boom extension.........................................155
		4.3.2 CHECKLIST: Unrigging the 26/32 m (85/121 ft) boom extension.......................................159
	4.4 Description of rigging work.............................................................................163
		4.4.1 Installing/dismantling section3 and section4....................................................163
			Installing..........................................................................................163
			Dismantling.........................................................................................164
		4.4.2 Installing/dismantling the lattice extension for the boom extension...............................165
			Installing..........................................................................................165
			Dismantling.........................................................................................166
		4.4.3 Hydraulic connection at the boom extension........................................................167
			On the 29 m (95 ft) boom extension..................................................................167
			On the 37 m (121ft) boom extension.................................................................169
		4.4.4 Electrical connection at the boom extension.......................................................171
			On the 29 m (95 ft) boom extension..................................................................171
			On the 37 m (121ft) boom extension.................................................................173
		4.4.5 Fold in/fold out the deflection sheave on section3...............................................175
			Folding out deflection sheave.......................................................................175
			Folding in deflection sheave........................................................................175
		4.4.6 Positioning/removing the hoist rope...............................................................176
			Positioning the hoist rope.........................................................................176
			Removing the hoist rope............................................................................176
			Possible reeving methods...........................................................................177
	4.5 Working with the boom extension.........................................................................179
	4.6 Driving with rigged truck crane and rigged boom extension..............................................181
		4.6.1 Driving route.....................................................................................182
		4.6.2 Boom positions and axle loads.....................................................................183
			Notes on the tables.................................................................................183
			29 m (95 ft) boom extension........................................................................184
			37 m (121 ft) boom extension.......................................................................185
		4.6.3 Driving the rigged crane..........................................................................186
	4.7 Maintenance work........................................................................................186
		4.7.1 Maintenance work M1, monthly......................................................................186
5 Auxiliary single-sheave boom top..............................................................................189
	5.1 Identification..........................................................................................189
	5.2 Installing/removing auxiliary single-sheave boom top....................................................191
		5.2.1 Installing the auxiliary single-sheave boom top...................................................191
		5.2.2 Dismantling the auxiliary single-sheave boom top..................................................192
	5.3 Rigging the auxiliary single-sheave boom top............................................................193
		5.3.1 Rigging in transport position.....................................................................193
		5.3.2 Rigging in working position.......................................................................194
		5.3.3 Attaching and removing the hoist rope.............................................................195
			Possible reeving methods............................................................................195
		5.3.4 Setting the SLI...................................................................................196
		5.3.5 Lifting limit switch and anemometer...............................................................197
			Lifting limit switch................................................................................197
			Anemometer..........................................................................................198
	5.4 Operation with the auxiliary single-sheave boom top.....................................................199
	5.5 Turning loads with the auxiliary single-sheave boom top.................................................201
		5.5.1 Prerequisites.....................................................................................201
		5.5.2 Setting the SLI...................................................................................202
			Entering a reeving..................................................................................202
			Setting the SLI to the auxiliary hoist..............................................................203
		5.5.3 Turning a load....................................................................................204
	5.6 Driving with rigged truck crane and rigged auxiliary single-sheave boom top.............................206
6 Heavy load lattice extension..................................................................................209
	6.1 Identification..........................................................................................209
	6.2 Attaching and securing the heavy load lattice extension.................................................211
		6.2.1 Slinging point....................................................................................211
		6.2.2 Securing the heavy load lattice extension with guide rope.........................................212
	6.3 Installing/removing the heavy load lattice extension....................................................213
		6.3.1 Installing the heavy load lattice extension.......................................................213
		6.3.2 Removing the heavy load lattice extension.........................................................215
	6.4 Rigging the heavy load lattice extension................................................................217
		6.4.1 Rigging in transport position.....................................................................217
		6.4.2 Rigging in working position.......................................................................219
		6.4.3 Setting the angle position of the heavy load lattice extension....................................221
			Installing/ removing the chain hoist................................................................221
			Setting the angle position..........................................................................222
		6.4.4 Attaching and removing the hoist rope.............................................................223
			Possible reeving methods on the heavy load lattice extension........................................224
		6.4.5 Lifting limit switch and anemometer...............................................................225
			Lifting limit switch................................................................................225
			Anemometer..........................................................................................226
		6.4.6 Transportation on a separate vehicle..............................................................227
	6.5 Operation with the heavy load lattice extension.........................................................229
		6.5.1 Setting the SLI...................................................................................230
		6.5.2 Raising and setting down the main boom............................................................232
			Raising.............................................................................................232
			Setting down........................................................................................232
		6.5.3 Telescoping with rigged heavy load lattice extension..............................................233
		6.5.4 Information about the SLI shutdown................................................................234
		6.5.5 Procedure if the permissible wind speed is exceeded...............................................234
		6.5.6 Information about the main boom operation when the heavy load lattice extension is folded/r.......235
	6.6 Turning loads with the heavy load lattice extension.....................................................237
		6.6.1 Prerequisites.....................................................................................237
		6.6.2 Setting the SLI...................................................................................238
			Entering a reeving..................................................................................238
			Setting the SLI to the auxiliary hoist..............................................................239
		6.6.3 Turning a load....................................................................................240
	6.7 Driving with rigged truck crane and rigged heavy load lattice extension.................................243
7 Index.........................................................................................................247
	A...........................................................................................................249
	B...........................................................................................................249
	E...........................................................................................................249
	H...........................................................................................................250
	I...........................................................................................................250
	L...........................................................................................................250
	M...........................................................................................................252
	P...........................................................................................................252
	S...........................................................................................................252
	T...........................................................................................................252

GROVE GMK 5220 OPERATING INSTRUCTIONS LATTICE EXTENSION MANUAL – PDF DOWNLOAD:

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