Page 1 Operating instructions for lattice extension Serial number: 2 084 770 en 08.05.2003...
Page 2 Original documents of Deutsche GROVE GmbH are marked with the blue serial number of the truck crane on the cover page. Duplications and print-outs of data carriers on which Deutsche GROVE GmbH has delivered this document are also not subject to the revision service. ©...
Page 3 The following chapters are contained in these operating instructions: 1 Important information 2 Transport dimensions and weights 3 Two-stage swing-away lattice extension 4 Boom extension 5 Auxiliary single-sheave boom top 6 Heavy load lattice extension Alphabetical index...
Page 5: Table Of Contents
Table of content Important information ....1 - 1 About these operating instructions ..... . . 1 - 1 Basic safety instructions .
Page 6 Centre of gravity positions for slinging ..... 3 - 4 Check lists for rigging work ......3 - 5 3.4.1 Overview of the required rigging work .
Page 7 3.10.3 Driving the rigged crane ......3 - 77 3.11 Malfunction when working with lattice extension! ....3 - 80 3.12 Maintenance work .
Page 8 5.2.2 Removing the auxiliary single-sheave boom top ....5 - 4 Rigging the auxiliary single-sheave boom top ....5 - 5 5.3.1 Rigging in transport position .
Page 9: Important Information
Prerequisites for The lattice extensions described in these operating instructions may only assembly and be operated together with a GROVE GMK 5100 truck crane whose serial operation number is identical with the serial number that is marked on the lattice ex- tensions.
Page 10: Basic Safety Instructions
Important information 1.2 Basic safety instructions Basic safety instructions 1.2.1 Warnings and symbols The following definitions and symbols are used in the operating instructi- ons to highlight particularly important information: This symbol indicates hazards related to the described operation that may cause personal injury.
Page 11: Proper Use
Important information 1.3 Proper use Proper use The truck crane GMK 5100 was constructed in accordance with state of the art 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.
Page 12 Important information 1.3 Proper use 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 gear, –...
Page 13: Organizational Measures
Important information 1.4 Organizational measures Organizational measures The operating instructions and the lifting capacity table should be kept in the truck crane for immediate access at all times and must not be remo- ved from the truck crane. You need to have read and understood the ope- ration and safety instructions in these operating instructions and to com- ply with them when working.
Page 14 To avoid any damage, especially to electronic parts, there are certain steps you must take before doing any welding work. So always consult GROVE Product Support before doing any welding work. Ensure that both the prescribed periods and the periods specified in the operating and maintenance instructions for regular testing, inspection and maintenance work are maintained.
Page 15: Personnel Qualifications
Only trained, experienced personnel with special knowledge in the fields of hydraulics, pneumatics and electrical equipment may carry out main- tenance work on the truck crane. The Deutsche GROVE GmbH gives general and type-related crane opera- tor and technical courses. Operating instructions for lattice extension...
Page 16: Safety Instructions For Truck Crane Work
Important information 1.6 Safety instructions for truck crane work Safety instructions for truck crane work Carefully select a safe site for the truck crane to stand from where you can safely work. Walk around the truck crane before beginning crane work. Check the con- dition of the truck crane carefully using the check lists in the operating in- structions.
Page 17 Important information 1.6 Safety instructions for truck crane work Support the truck crane with the supporting span for the current rigged counterweight before turning the superstructure. Ensure that the truck crane is horizontally aligned before carrying out crane work. Only use equipment (counterweight sections, lattice extensions) that be- longs to your truck crane.
Page 18: The Units Of Measurement In Us Units
Important information 1.7 The units of measurement in US units The units of measurement in US units These operating instructions use mainly metric units of measurement. Should you be working in a country that uses US units of measurement, refer to the following table for a comparison of the units. –...
Page 19: Transport Dimensions And Weights
Transport dimensions and weights 2.1 In metric units Transport dimensions and weights In metric units This section contains the transport dimensions and weights of the lattice extensions in metric units. 2.1.1 Two-stage swing-away lattice extension and boom extension Description Length x width x Weight (kg) height (m) Two-stage swing-away lattice...
Page 20: In Us Units
Transport dimensions and weights 2.2 In US units In US units This section contains the transport dimensions and weights of the lattice extensions in US units. 2.2.1 Two-stage swing-away lattice extension and boom extension Description Length x width x Weight (lbs) height (ft) Two-stage swing-away lattice 37.73 x 3.28 x 4.92...
Page 21: Two-Stage Swing-Away Lattice Extension (Additional Equipment)
If you wish to use the two-stage swing-away lattice extension on several GROVE Truck Cranes, the two-stage swing-away lattice extension sections must be adjusted for the corresponding cranes and labelled with all of the respective serial numbers.
Page 22 Two-stage swing-away lattice extension (additional equipment) 3.1 Identification of the two-stage swing-away lattice extension Serial numbers The 11 m section consists of a fixed section and an inclinable section. on 11 m section On the inclinable section the serial number (1) is at the front on a sheet to the right of the deflection sheave.
Page 23: Assembly Of Lattice Extensions
Two-stage swing-away lattice extension (additional equipment) 3.2 Assembly of lattice extensions Assembly of lattice extensions 11 m swing-away lattice extension (36 ft swing-away lattice extension) 11 m section (36 ft section) 18 m swing-away lattice extension (59 ft swing-away lattice extension) 11 m section 7 m section (36 ft section)
Page 24: Centre Of Gravity Positions For Slinging
Two-stage swing-away lattice extension (additional equipment) 3.3 Centre of gravity positions for slinging Centre of gravity positions for slinging Observe the centres of gravity of the lattice extension and the swing-away lattice extension when you sling the lattice extension to an auxiliary crane for removal or installation.
Page 25: Check Lists For Rigging Work
Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work Check lists for rigging work 3.4.1 Overview of the required rigging work There are different initial states for rigging the lattice extension, depen- ding on whether – the lattice extension is folded at the side of the main boom or –...
Page 26: Checklist: Installing Two-Stage Swing-Away Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 3.4.2 CHECKLIST: Installing two-stage swing-away lattice extension This checklist is not equivalent to complete operating instructions. There are accompanying instructions, which are indicated by cross-references. Observe the warning and safety information given there! Requirements –...
Page 27: Checklist: Removing (Two-Stage) Swing-Away Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 5. If the lattice extension is to be folded up at the side of the main boom, ➠ Folding the run-up rail in/out , p. 3-32. fold out run-up rail; 6.
Page 28 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 2. Carry out all of the rigging work for a rigged 18 m two-stage swing- away lattice extension listed in the CHECKLIST: Removing 18 m two- stage swing-away lattice extension up until and inclusive of point 13, ➠...
Page 29: Checklist: Rigging The 11 M Swing-Away Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 3.4.4 CHECKLIST: Rigging the 11 m swing-away lattice extension This checklist is not a complete operating manual. There are accompany- ing instructions, which are indicated by cross-references. Observe the warning and safety information given there! 1.
Page 30 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 6. Release connection at the pivot point between 11 m section and 7 m ➠ Pin connections on the lattice extension, p. 3-42. section; 7. If only the 11 m sectionis folded at the side of the main boom, remove connection between 11 m section and main boom (rear);...
Page 31 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work ➠ Swivelling the lattice 12. Swing 11 m section in front of the main boom; extension during rigging, p. 3-46. 13. Pin 11 m section onto main boom head, on left-hand side; ➠...
Page 32 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 18. Move anemometer from the head of the main boom to the head of ➠ Anemometer on lattice extension, p. 3-60. the 11 m section; 19. Move lifting limit switch from the head of the main boom to the head ➠...
Page 33: Checklist: Unrigging The 11 M Swing-Away Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 3.4.5 CHECKLIST: Unrigging the 11 m swing-away lattice extension This checklist is not a complete operating manual. There are accompany- ing instructions, which are indicated by cross-references. Observe the warning and safety information given there! ➠...
Page 34 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work ➠ Adjusting angle on the lattice extension , 7. Set angle at 0° if necessary; p. 3-48. ➠ 8. Fold in deflection sheave on 11 m section; Folding deflection sheave on 11 m section in/out , p.
Page 35 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 13. Swivel the 11 m section towards the main boom until the connection between the main boom (in the front area) and the 11 m section enga- ➠ Swivelling the lattice extension during rigging, p.
Page 36 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 18. If the 7 m section is not available, swivel the 11 m section on the run- ➠ Connections in the rear up rail onto the main boom and lock it there; area, p.
Page 37 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 3.4.6 CHECKLIST: Rigging the 18 m two-stage swing-away lattice extension This checklist is not a complete operating manual. There are accompany- ing instructions, which are indicated by cross-references. Observe the warning and safety information given there! 1.
Page 38 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work ➠ Securing 7. Secure lattice extension on main boom with guide rope; lattice extension with cord, p. 3-28. 8. Unlock and remove connection between 11 m section and main ➠...
Page 39 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 13. Release connection between 7 m section and 11 m section and swivel 7 m section in front of the 11 m section; ➠ Connections in the middle area, p. 3-35. ➠...
Page 40 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 19. Move anemometer from the head of the main boom to the head of ➠ Anemometer on lattice extension – 18 m two-stage the 7 m section; swing-away lattice extension, p. 3-60. 20.
Page 41 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 3.4.7 CHECKLIST: Unrigging the 18 m two-stage swing-away lattice extension This checklist is not a complete operating manual. There are accompany- ing instructions, which are indicated by cross-references. Observe the warning and safety information given there! ➠...
Page 42 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 7. Detach electrical connection between 7 m section and 11 m section; ➠ Electrical connection on the lattice extension – 18 m two-stage swing-away lattice extension, p. 3-57. ➠...
Page 43 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 13. Swivel the 7 m section to the side of the 11 m section until the connec- tion between the 7 m section and the 11 m section engages; ➠...
Page 44 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 19. Secure 11 m section on the main boom with locking pin; ➠ Connections in the front area, p. 3-34. 20. Remove left pin between 11 m section and main boom head; ➠...
Page 45 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work 24. Check whether the lattice extension is in transport position; ➠ Checking transport condition, p. 3-29. ➠ 25. Fold in the run-up rail; Folding run-up rail in/out , p. 3-32. ➠...
Page 46 Two-stage swing-away lattice extension (additional equipment) 3.4 Check lists for rigging work Blank page 3 - 26 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 47: Description Of Rigging Work
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Description of rigging work 3.5.1 Preparing the truck crane for rigging The data in this section also applies to the rigging of the boom extension. Do not override the SLI when lowering into a horizontal position! If these requirements are met, lowering into the horizontal position with lattice extension/boom extension and a slewing range of 360°...
Page 48 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work – The main boom is fully retracted (0/0/0/0). – The telescoping cylinder is locked in telescopic section and is retract- ed as far as possible just before the start of rigging so that all teles- coping parts are fully retracted.
Page 49: Checking The Transport Condition
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.2 Checking the transport condition For transportation you must establish certain connections between both parts of the lattice extension. The connections which need to be estab- lished depend on whether the lattice extension: –...
Page 50 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3 - 30 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 51 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Transport condi- The transport condition with the lattice extension folded at the side is tion with lattice created when all of the following connections are established. extension folded • Check the connections and establish them if necessary. at the side If 7 m section and 11 m section are folded at the side: –...
Page 52: Folding The Run-Up Rail Out/In
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.3 Folding the run-up rail out/in The run-up rail is folded out for rigging and folded back in for on-road driving after derigging. Folding the run-up rail out • Pull the locking bar (1) downwards against the spring force, and out of the bore (3).
Page 53: Connections With Folded Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.4 Connections with folded lattice extension The lattice extension is turned sideways to the main boom in folded position. In this position there are four areas where various connections have to be disconnected and reconnected again during rigging and unrigging: –...
Page 54 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Risk of accidents from a falling lattice extension. Be sure that the 11 m part is locked on the main boom head in the front right, before you loosen the connection in the front area. This will prevent the lattice extension from falling and causing injury to you or other per- sons.
Page 55 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Connections in the middle area Connection between 7 m section and 11 m section The connection must be made: – for transportation, – for installation and removal, – when unrigging the 18 m two-stage swing-away lattice extension. The connection must be disconnected: –...
Page 56 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Connections The 7 m section can be fastened to the run-up rail with a pin. on the run-up rail The connection must be made: – when unrigging the 18 m two-stage swing-away lattice extension, –...
Page 57 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Connections in Connection between 7 m section and main boom the rear area The connection must be made: – when unrigging the 18 m two-stage swing-away lattice extension, – for operation with the 11 m swing-away lattice extension. The connection must be separated: –...
Page 58 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Connection between 11 m section and main boom This connection does not apply to truck cranes that are supplied with an 18 m two-stage swing-away lattice extension. This connection must be established if the 11 m swing-away lattice exten- sion is folded in to the side during unrigging.
Page 59: Pin Connections On The Main Boom Head
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.5 Pin connections on the main boom head The lattice extension and main boom head are connected on the bearing points using pins. The pins can be found in holders on the lattice extensi- on and are secured there with retaining pins.
Page 60 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Establishing For these connections you will find are three short pins and one long pin connections in holders on the fixed part of the 11 m section. The long pin is always placed last, into the bottom bearing point on the left-hand side.
Page 61 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work • Secure the lattice extension with a guide rope before removing any con- Remove connections nections. Connections on the left side • Remove the retaining pins from pins (1) and (2).
Page 62: Pin Connections On The Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.6 Pin connections on the lattice extension The 11 m section and the 7 m section are connected on the bearing points using pins. The pins are inserted into the 7 m section, at the rear of the retaining sheet on the upper boom.
Page 63 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work • Swivel the 7 m section in front of the 11 m section until the bearing Connection on the left side points on the left side are in alignment. Establishing connection •...
Page 64 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Blank page 3 - 44 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 65: Swivelling Lattice Extension Onto The Main Boom Head
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.7 Swivelling lattice extension onto the main boom head This section describes how the lattice extension is swung – onto the main boom head for rigging and – onto the main boom basic section for unrigging. The lattice extension must be swung onto the main boom head from transport position so that the 11 m section can be fastened to the right side of the main boom head with pins.
Page 66: Swivelling The Lattice Extension When Rigging
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.8 Swivelling the lattice extension when rigging This section describes the swinging of the lattice extension during rig- ging. If you want to swing the lattice extension for unrigging, proceed in the opposite order.
Page 67 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work If a helper is holding the guide rope, he can now pull the lattice extension from the run-up rail and swing it in front of the main boom head. If you are alone and have attached the guide rope to the crane when securing, the lattice extension will now only swing until the guide rope is tight.
Page 68: Adjusting Angle On The Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.9 Adjusting angle on the lattice extension You can set three different angles for the lattice extension (0°, 20° and 40°). To set the angles, attach the lattice extension to the hoist cable and in- cline by means of the hoist.
Page 69 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Risk of damage during telescoping! Avoid telescoping the main boom as long as the hoist cable is attached to the lattice extension. If telescoping is absolutely necessary, make sure hoist cable will not tear by giving it sufficient slack.
Page 70 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Pin connections On each side there is a retaining pin in the strut above the point of adjust- for the angle ment which is used for setting the angle of inclination. The retaining pins are inserted into different bores, depending on the de- gree of inclination of the lattice extension.
Page 71: Folding Deflection Sheave On 11 M Section Out/In
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.10 Folding deflection sheave on 11 m section out/in To prevent the hoist cable dragging on the main boom or the lattice exten- sion during operation with the lattice extension, the hoist cable is guided via a deflection sheave.
Page 72: Positioning/Removing The Hoist Cable
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.11 Positioning/removing the hoist cable Risk of accidents due to falling parts! Always secure the hoist cable holding rollers and rods with retaining pins. This prevents elements coming loose, falling down and injuring people. When setting an When setting an angle of 40°...
Page 73 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 11 m swing-away lattice extension 18 m two-stage swing-away lattice extensi- • Remove the hoist cable holding rollers and rods (1). Positioning hoist rope • Guide the hoist rope via the deflection sheaves (4), (3) and via the head sheave (2) on the 11 m section or on the 18 m section.
Page 74 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Possible reeving The hoist cable can be reeved once or twice; methods on the swing-away lattice extension 1 fall Hook tackle, max. lifting capacity 8 t max. lifting capacity with the GMK 5100: for simple reeving 7 t (15.432 lbs) 2 fall...
Page 75: Electrical Connection On The Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.12 Electrical connection on the lattice extension The SLI, the lifting limit switch and the lowering limit switch are connec- ted via the electrical connection on the lattice extension. 11 m swing-away For the 11 m swing-away lattice extension the electrical connection is lattice extension...
Page 76 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work • Check if the dummy plug (2) is inserted in the socket (1) at the front of the 11 m section. 3 - 56 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 77 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 18 m two-stage For the 18 m swing-away lattice extension an additional connection is swing-away latti- made or disconnected between the 11 m section and the 7 m section as ce extension well as the electrical connection of the 11 m swing-away lattice extension.
Page 78: Lifting Limit Switch On The Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.13 Lifting limit switch on the lattice extension The functions Raise hoist, extend main boom, extend main boom and Lower main boom are monitored during operation with the lattice extension by the lifting limit switch on the lattice extension and are switched off when the lifting limit switch is actuated.
Page 79 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work On the 18 m two- stage swing- away lattice ex- tension For operation with the 18 m two-stage swing-away lattice extension the connection for the lifting limit switch on the 11 m section must be overrid- den with a short-circuit plug.
Page 80: Anemometer On The Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.14 Anemometer on the lattice extension The same anemometer is used for lattice extension and main boom. On 11 m swing-away lattice extension • Attach the anemometer (3) to the holder (2) on the head of the 11 m section and secure it with a retaining pin.
Page 81: Transportation On A Separate Vehicle
Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work 3.5.15 Transportation on a separate vehicle Only attach the lattice extension in such a way that it is positioned in the centre of gravity and always use lifting gear with sufficient lifting capaci- ty.
Page 82 Two-stage swing-away lattice extension (additional equipment) 3.5 Description of rigging work Blank page 3 - 62 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 83: 3.6 Raising And Setting Down The Main Boom With Rigged Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.6 Raising and setting down the main boom with rigged lattice extension Raising and setting down the main boom with rigged lattice extension The information in this section also applies to raising and setting down the main boom with a rigged boom extension.
Page 84 Two-stage swing-away lattice extension (additional equipment) 3.6 Raising and setting down the main boom with rigged lattice extension Blank page 3 - 64 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 85: Telescoping With Rigged Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.7 Telescoping with rigged lattice extension Telescoping with rigged lattice extension The main boom may become overloaded! If you telescope the main boom with a rigged lattice extension or boom extension, you must not rotate the superstructure at the same time. This prevents the main boom becoming subject to additional side forces and increased vibration and becoming overloaded.
Page 86 Two-stage swing-away lattice extension (additional equipment) 3.7 Telescoping with rigged lattice extension Blank page 3 - 66 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 87: Operation With The Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.8 Operation with the lattice extension Operation with the lattice extension The information in this section also applies to operation with the boom ex- tension. Observe the following safety instruction before working with the boom extension.
Page 88: Procedure If The Permissible Wind Speed Is Exceeded
Two-stage swing-away lattice extension (additional equipment) 3.8 Operation with the lattice extension 3.8.2 Procedure if the permissible wind speed is exceeded Strong winds lead to the truck crane being overloaded. Closely observe therefore the instructions in the operation instructions GMK 5100; ➠...
Page 89: Turning Loads With The Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.9 Turning loads with the lattice extension Turning loads with the lattice extension When turning loads it is necessary to employ a two-hook operation. The only type of two-hook operation technically possible and protected by the SLI is described in this chapter using the turning of loads as an examp- Risk of accidents due to overloading! Lifting a load with two hooks is permissible only if the following instruc-...
Page 90: Setting Sli
Two-stage swing-away lattice extension (additional equipment) 3.9 Turning loads with the lattice extension 3.9.2 Setting SLI For two-hook operation, both hoists must be activated on the SLI. It is advisable to enter the reevings for both hoists at the start. The values are stored and called up directly when switching hoisting gears.
Page 91 Two-stage swing-away lattice extension (additional equipment) 3.9 Turning loads with the lattice extension • Switch the main hoist on by pressing the Main hoist shutdown rocker ü switch up. On the display lamps Hoists, lamp is now lit for the auxiliary hoist and lamp is flashing for the main hoist.
Page 92 Two-stage swing-away lattice extension (additional equipment) 3.9 Turning loads with the lattice extension C0183 • Lift the load fully with the lattice extension. • Only now should you attach the load to the hook block of the main boom as well. •...
Page 93: Driving With Rigged Crane And Lattice Extension Installed
Two-stage swing-away lattice extension (additional equipment) 3.10 Driving with rigged crane and lattice extension installed 3.10 Driving with rigged crane and lattice extension installed This section describes how you can move the truck crane with an installed counterweight and rigged lattice extension. Risk of accidents! It is forbidden to move the truck crane with a load on the hook.
Page 94: Position Of The Boom
Two-stage swing-away lattice extension (additional equipment) 3.10 Driving with rigged crane and lattice extension installed 3.10.2 Position of the boom The vehicle may only be moved if certain conditions are met. The boom may have to be moved to a specified position, depending on the installed counterweight.
Page 95 Two-stage swing-away lattice extension (additional equipment) 3.10 Driving with rigged crane and lattice extension installed 11 m swing-away The following table only applies if the 11 m swing-away lattice extension lattice extension is rigged. Tables applying if 18 m two-stage swing-away lattice extension ➠...
Page 96 Two-stage swing-away lattice extension (additional equipment) 3.10 Driving with rigged crane and lattice extension installed 18 m two-stage The following table only applies if the 18 m two-stage swing-away lattice swing-away latti- extension is rigged. Tables applying if 11 m two-stage swing-away lattice extension is rigged; ➠...
Page 97: Driving The Rigged Crane
Two-stage swing-away lattice extension (additional equipment) 3.10 Driving with rigged crane and lattice extension installed 3.10.3 Driving the rigged crane Locking the su- Before the truck crane is moved, the superstructure must be locked to the ➠ GMK 5100 Operating Instructions, part 2 Superstructure – Crane perstructure and carrier;...
Page 98 Two-stage swing-away lattice extension (additional equipment) 3.10 Driving with rigged crane and lattice extension installed Switch on sepa- Before driving with the rigged crane you must switch on the separate rate steering steering: • Switch on the Level adjustment system key switch. C0018 •...
Page 99 Two-stage swing-away lattice extension (additional equipment) 3.10 Driving with rigged crane and lattice extension installed • Steer the truck crane only when it is moving and avoid sudden steering movements! When the surface is uneven the truck crane must be raised with the outrig- ger cylinders, horizontally aligned and then re-lowered;...
Page 100: Malfunction When Working With Lattice Extension
Two-stage swing-away lattice extension (additional equipment) 3.11 Malfunction when working with lattice extension! 3.11 Malfunction when working with lattice extension! The information in the following table applies to malfunctions during operation with the 11/18 m lattice exension as well as to operation with the 26/34 m boom extension.
Page 101: Maintenance Work
Two-stage swing-away lattice extension (additional equipment) 3.12 Maintenance work 3.12 Maintenance work 3.12.1 Modules requiring protection during cleaning work Provide protection for the following electrical parts during cleaning work: – the control box on the fixed part of the 11 m section (1) and –...
Page 102: Maintenance Work M1, Monthly
Two-stage swing-away lattice extension (additional equipment) 3.12 Maintenance work 3.12.2 Maintenance work M1, monthly For lubricating the pins and support rollers, use the same grease as stated ➠ in the Maintenance Manual for attach pins and socket pins; GMK 5100 Maintenance Manual, Overview of maintenance work –...
Page 103: Boom Extension (Additional Equipment)
For technical reasons a truck crane may only be set with one boom extension. If you wish to use the boom extension on several GROVE truck cranes, the parts of the boom extension must be adjusted for these cranes and label- led with all of the respective serial numbers.
Page 104: Slinging Points
Boom extension (additional equipment) 4.1 Identification and slinging points Serial numbers on the 8 m sections On the 8 m sections the serial number (1) is at the front on a sheet. 4.1.2 Slinging points This section shows the slinging points on the 8 m sections. Attach the sections on these slinging points only.
Page 105: Assembly Of Boom Extensions
Boom extension (additional equipment) 4.2 Assembly of boom extensions Assembly of boom extensions 26 m boom extension (85 ft boom extension) 8 m section 11 m section 7 m section (26 ft section) (36 ft section) (23 ft section) 34 m boom extension (112 ft boom extension) 8 m section 8 m section...
Page 106 Boom extension (additional equipment) 4.2 Assembly of boom extensions Blank page 4 - 4 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 107: Check Lists For Rigging Work
Boom extension (additional equipment) 4.3 Check lists for rigging work Check lists for rigging work 4.3.1 CHECKLIST: Installing the 26 m/34 m boom extension This checklist is not equivalent to complete operating instructions. There are accompanying instructions, which are indicated by cross-references. Observe the warning and safety information given there! Requirements –...
Page 108 Boom extension (additional equipment) 4.3 Check lists for rigging work 6. Attach guide rope to the head of the 7 m section. 7. Release connection between 7 m section and 11 m section; ➠ Connections in the middle area, p. 3-35. 8.
Page 109 Boom extension (additional equipment) 4.3 Check lists for rigging work 12. Place hoist cable over all the deflection sheaves and the head sheave ➠ Positioning/removing hoist cable , p. 4-16. of the 7 m section; ➠ 13. Adjust angle if necessary; Adjusting angle on the lattice extension , p.
Page 110: Checklist: Removing The 26 M/34 M Boom Extension
Boom extension (additional equipment) 4.3 Check lists for rigging work 18. Enter SLI code according to Lifting capacity table for the actual rigging 00== mode of the truck crane with the 26 m or 34 m boom extension, ➠ Setting the rigging mode GMK 5100 Operating Instructions, part 2 Super- structure –...
Page 111 Boom extension (additional equipment) 4.3 Check lists for rigging work ➠ Positioning/removing the 5. Reeve out hoist cable from the hook block; hoist cable , p. 3-52. ➠ 6. Remove anemometer (additional equipment); Anemometer on the lat- tice extension, p. 3-60. ➠...
Page 112 Boom extension (additional equipment) 4.3 Check lists for rigging work 11. Remove the locking pins on the left-hand side between 7 m section and 11 m section; ➠ Pin connections on the lattice extension , p. 3-42. 12. Swivel the 7 m section onto the 11 m section side until the connection between the two sections engages;...
Page 113: Description Of Rigging Work
Boom extension (additional equipment) 4.4 Description of rigging work Description of rigging work 4.4.1 Installing/disassembling 8 m sections – In order to rig the 26 m boom extension you must install the 8 m secti- on with support roller in front of the main boom head. –...
Page 114 Boom extension (additional equipment) 4.4 Description of rigging work 4.4.2 Installing/removing two-stage swing-away lattice extension for boom extension This section describes the installation and removal of the folded two-sta- ge swing-away lattice extension. You can also install the two-stage swing-away lattice extension which has been folded in front of the other in front of an 8 m section (e.g.
Page 115: Extension
Boom extension (additional equipment) 4.4 Description of rigging work 4.4.3 Electrical connection on the boom extension This section describes the electrical connections on the 8 m sections. For establishing electrical connection on the two-stage swing-away lattice ➠ extension; Electrical connection on the lattice extension, p. 3-55. Connections on the 8 m sections At the rear of the 8 m sections there is a...
Page 116 Boom extension (additional equipment) 4.4 Description of rigging work Establishing For the 26 m boom extension electrical • Connect the cable of the 8 m section to the socket on the main boom connections head. • Connect the cable of the 11 m section on the socket at the front of the 8 m section.
Page 117: Folding Out/In The Deflection Sheaves On The 8 M Sections
Boom extension (additional equipment) 4.4 Description of rigging work 4.4.4 Folding out/in the deflection sheaves on the 8 m sections This section describes only the folding in and out of the deflection sheave on the 8 m section. To fold the deflection sheaves in and out on the ➠...
Page 118: Positioning/Removing The Hoist Cable
Boom extension (additional equipment) 4.4 Description of rigging work 4.4.5 Positioning/removing the hoist cable Risk of accidents due to falling parts! Always secure the hoist cable holding rollers and rods with retaining pins. This prevents elements coming loose, falling down and injuring people. When setting an When setting an angle of 20°...
Page 119 Boom extension (additional equipment) 4.4 Description of rigging work 26 m boom extension 34 m boom extension • Remove the hoist cable holding rollers and rods (1). • Guide the hoist cable via the deflection sheaves (5), (4), (3) and via the head sheave (2) on the 7 m section for both boom extensions.
Page 120 Boom extension (additional equipment) 4.4 Description of rigging work Blank page 4 - 18 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 121: Driving With A Rigged Crane If Boom Extension Is Rigged
Boom extension (additional equipment) 4.5 Driving with a rigged crane if boom extension is rigged Driving with a rigged crane if boom extension is rig- This section describes how you can move the truck crane with an installed counterweight and rigged lattice extension or boom extension. Risk of accidents! It is forbidden to move the truck crane with a load on the hook.
Page 122: Position Of The Boom
Boom extension (additional equipment) 4.5 Driving with a rigged crane if boom extension is rigged 4.5.2 Position of the boom The vehicle may only be moved if certain conditions are met. The boom may have to be moved to a specified position, depending on the installed counterweight.
Page 123 Boom extension (additional equipment) 4.5 Driving with a rigged crane if boom extension is rigged 26 m boom The following table only applies if the 26 m boom extension is rigged. ➠ extension Tables applying if 34 m boom extension is rigged; p.
Page 124: Driving The Rigged Crane
Boom extension (additional equipment) 4.5 Driving with a rigged crane if boom extension is rigged 34 m boom The following table only applies if the 34 m boom extension is rigged. ➠ extension Tables applying if 26 m boom extension is rigged; p.
Page 125 Boom extension (additional equipment) 4.5 Driving with a rigged crane if boom extension is rigged To do this push down the Slewing gear permanent brake rocker switch. The Slewing gear permanent brake applied indicator lamp lights up when slewing gear permanent brake is applied. If the crane engine stops the slewing gear permanent brake is automat- ically applied.
Page 126 Boom extension (additional equipment) 4.5 Driving with a rigged crane if boom extension is rigged • Switch on separate steering by releasing the Separate steering rocker switch and pressing it down. Damage may occur to steering linkage! Before driving with the rigged crane always switch on separate steering and steer the truck crane only when the vehicle is moving.
Page 127: Maintenance Work
Boom extension (additional equipment) 4.6 Maintenance work Maintenance work 4.6.1 Maintenance work M1, monthly For lubricating the pins, use the same grease as stated in the Maintenance ➠ Manual for attach pins and socket pins; GMK 5100 Maintenance Manual, Overview of maintenance work – Maintenance plan M1. •...
Page 128 Boom extension (additional equipment) 4.6 Maintenance work Blank page 4 - 26 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 129: Auxiliary Single-Sheave Boom Top (Additional Equipment)
Operate the truck crane only with the auxiliary single-sheave boom top that has the identical serial number. If you wish to use the boom top on several GROVE truck cranes, it needs to be adapted to the corresponding crane and marked with all the serial numbers.
Page 130 Auxiliary single-sheave boom top (additional equipment) 5.1 Identification Blank page 5 - 2 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 131: Installing/Removing Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top (additional equipment) 5.2 Installing/removing auxiliary single-sheave boom top Installing/removing auxiliary single-sheave boom top Risk of accidents if the boom top should fall off! During installation and removal, always use the proper materials with ➠ Transport dimensions and weights, sufficient load bearing capacities;...
Page 132: Removing The Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top (additional equipment) 5.2 Installing/removing auxiliary single-sheave boom top 5.2.2 Removing the auxiliary single-sheave boom top The boom top is mounted to a holding device on the left side of the main boom head. When removing, the locking pins are first taken out of the front bore holes (1) in the holding device.
Page 133: Rigging The Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top (additional equipment) 5.3 Rigging the auxiliary single-sheave boom top Rigging the auxiliary single-sheave boom top 5.3.1 Rigging in transport position On the left side of the main boom head there is a holding device. In transport position, the boom top is connected to the rear bore holes (1) on the holding device.
Page 134: Rigging In Working Position
Auxiliary single-sheave boom top (additional equipment) 5.3 Rigging the auxiliary single-sheave boom top 5.3.2 Rigging in working position On the left side of the main boom head there is a holding device. In working position, the auxiliary single-sheave boom top is attached to the main boom head at both bore holes.
Page 135: Attaching And Removing Hoist Cable
Auxiliary single-sheave boom top (additional equipment) 5.3 Rigging the auxiliary single-sheave boom top 5.3.3 Attaching and removing hoist cable • Remove the cable holding rods (1) from the head of the main boom and from the auxiliary single-sheave boom top. •...
Page 136: Lifting Limit Switch And Anemometer
Auxiliary single-sheave boom top (additional equipment) 5.3 Rigging the auxiliary single-sheave boom top 5.3.5 Lifting limit switch and anemometer In operation • Pull the plug of the connecting cable from the dummy socket (2). • Unwind the connecting cable from the hol- ders (3).
Page 137: Turning Loads With The Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top (additional equipment) 5.4 Turning loads with the auxiliary single-sheave boom top Turning loads with the auxiliary single-sheave boom top When turning loads, it is necessary to employ a two-hook operation. The only type of two-hook operation technically possible and protected by the SLI is described in this chapter using the turning of loads as an example.
Page 138 Auxiliary single-sheave boom top (additional equipment) 5.4 Turning loads with the auxiliary single-sheave boom top Setting SLI For two-hook operation, both hoists must be activated on the SLI. It is advisable to enter the reevings for both hoists at the start. The values are stored and called up directly when switching hoisting gears.
Page 139 Auxiliary single-sheave boom top (additional equipment) 5.4 Turning loads with the auxiliary single-sheave boom top • Switch the main hoist on by pushing up the Main hoist shutdown rocker ü switch. • On the display lamps Hoists, lamp is now lit for the auxiliary hoist and lamp is flashing for the main hoist.
Page 140 Auxiliary single-sheave boom top (additional equipment) 5.4 Turning loads with the auxiliary single-sheave boom top C0985 • Lift the load completely off the ground with the auxiliary single-sheave boom top. • Only now should you attach the load to the hook block of the main boom as well.
Page 141: Heavy Load Lattice Extension
Operate the truck crane only with the heavy load lattice extension that has the identical serial number as the truck crane. If you wish to use the lattice extension on several GROVE truck cranes, the extension must be adjusted for these cranes and labelled with all of the respective serial numbers.
Page 142 Heavy load lattice extension 6.1 Identification Blank page 6 - 2 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 143: Mount / Remove Heavy Load Lattice Extension
Heavy load lattice extension 6.2 Mount / remove heavy load lattice extension Mount / remove heavy load lattice extension Risk of accidents due to falling heavy load lattice extension. During installation and removal, always use the proper materials with suf- ➠...
Page 144: Removing The Heavy Load Lattice Extension
Heavy load lattice extension 6.2 Mount / remove heavy load lattice extension 6.2.2 Removing the heavy load lattice extension When driving on public roads, the heavy load lattice extension must al- ways be removed. The heavy load lattice extension is mounted to a holding device on the left side of the main boom head.
Page 145: Rigging Work Check Lists
Heavy load lattice extension 6.3 Rigging work check lists Rigging work check lists 6.3.1 CHECK LIST: Changing the heavy load lattice extension This checklist is not equivalent to complete operating instructions. There are accompanying instructions, which are indicated by cross-references. Comply with the warning and safety information given there.
Page 146 Heavy load lattice extension 6.3 Rigging work check lists ➠ Possible ree- 5. Lay the auxiliary hoist rope and reeve it on hook block; vings on the heavy load lattice extension , p. 6-16. ➠ 6. Mount lifting limit switch weight; GMK 5100 Operating instructions, Part 2, Superstructure –...
Page 147: Check List: Unrigging Heavy Load Lattice Extension
Heavy load lattice extension 6.3 Rigging work check lists 6.3.2 CHECK LIST: Unrigging heavy load lattice extension This checklist is not equivalent to complete operating instructions. There are accompanying instructions, which are indicated by cross-references. Comply with the warning and safety information given there! Requirement: –...
Page 148 Heavy load lattice extension 6.3 Rigging work check lists 6. Fold out holding rods and pin them on the heavy load lattice extensi- ➠ p. 6-12. 7. Swivel the heavy load lattice extension on the main boom head; ➠ p. 6-9. 6 - 8 2 084 770 en Operating instructions for lattice extension...
Page 149: Rigging / Unrigging The Heavy Load Lattice Extension
Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension Rigging / unrigging the heavy load lattice extension 6.4.1 Rigging the heavy load lattice extension Prerequisites The following requirements must be met before rigging of the heavy load lattice extension: –...
Page 150 Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension Swiveling the For transporting on the construction site, the heavy load lattice extension lattice extension is slewed sideways on the main boom and is secured with a pin (2) with in front of main the retaining pin.
Page 151 Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension Slew the heavy load lattice exten- sion onto the main boom • Release the retaining pins from the pins (4) and remove them from the bores (1). •...
Page 152 Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension Folding and unfol- The holding rods (2) are folded in transport position and are fastened on ding of holding the heavy load lattice extension using both short pins (1) with retaining rods pins.
Page 153 Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension Swivel the heavy The heavy load lattice extension is retained by the pins (2) with retaining load lattice exten- pin in transport position. sion into working position The pin (2) connects the bores (1) in the holding device and the heavy load lattice extension.
Page 154 Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension Position and re- move the hoist rope • Remove the rope holding rods (1) on the main boom and the heavy load lattice ex- tension. • Guide the hoist rope of the auxiliary hoist unit with the rope end clamp over the left head sheave (2) on the main boom in the heavy load lattice extension (3) and out...
Page 155 Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension Possible reeving The hoist rope of the auxiliary hoist should be reeved only 1-fall or 2-fall methods on the on the heavy load lattice extension. heavy load lattice extension Hook tackle, maximum lifting capacity 8 t 1-fall...
Page 156 Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension Lifting limit switch and ane- mometer Lifting limit switch for operation • Pull the plug of the connecting cable from the dummy socket (2). • Unwind the connecting cable from the hol- ders (3).
Page 157: Removing The Heavy Load Lattice Extension
Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension 6.4.2 Removing the heavy load lattice extension Prerequisites The heavy load lattice extension is rigged, otherwise the same prereq- ➠ uisites apply as for rigging, p. 6-9. Sequence during Unrigging is done in the reverse order of rigging.
Page 158 Heavy load lattice extension 6.4 Rigging / unrigging the heavy load lattice extension Blank page 6 - 18 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 159: Operation With The Heavy Load Lattice Extension
Heavy load lattice extension 6.5 Operation with the heavy load lattice extension Operation with the heavy load lattice extension If a heavy load lattice extension is reeved during operation with the main boom, the loads given in the Lifting capacity tables decrease. The values which have to be taken off the loads are given in the Lifting capacity tables in their own table.
Page 160: Telescoping With Rigged Heavy Load Lattice Extension
Heavy load lattice extension 6.5 Operation with the heavy load lattice extension 6.5.1 Telescoping with rigged heavy load lattice extension The main boom may become overloaded! While you are telescoping the main boom with the rigged heavy load latti- ce extension, you may not simultaneously slew the superstructure. This prevents the main boom being subjected to additional side forces and increased vibration and becoming overloaded.
Page 161: Turning Loads With The Heavy Load Lattice Extension
Heavy load lattice extension 6.6 Turning loads with the heavy load lattice extension Turning loads with the heavy load lattice extension When turning loads it is necessary to employ a two-hook operation. The only type of two-hook operation technically possible and protected by the SLI is described in this chapter using the turning of loads as an example.
Page 162 Heavy load lattice extension 6.6 Turning loads with the heavy load lattice extension Setting SLI For two-hook operation, both hoists must be activated on the SLI. It is advisable to enter the reevings for both hoists at the start. The values are stored and called up directly when switching hoisting gears.
Page 163 Heavy load lattice extension 6.6 Turning loads with the heavy load lattice extension • Switch the main hoist on by pushing up the Main hoist shutdown rocker ü switch. • On the Hoists indicator lamps, lamp is now lit for the auxiliary hoist and lamp flashes for the main hoist.
Page 164 Heavy load lattice extension 6.6 Turning loads with the heavy load lattice extension C0985 • Lift the load completely off the ground with the heavy load lattice exten- sion. • Only now should you attach the load to the hook block of the main boom as well.
Page 165 Alphabetical index ➠ How to use the alphabetical index GMK 5100 Operating instructions. To avoid making the index unnecessarily long and unclear, we have not included every single element from the instrument panel. These elements, such as rocker switches, warning and indicator lamps as well as status displays are described and named in detail in the overviews of chapter 4 and 10 Description of the truck crane .
Page 166 Blank page Alphabetical index - 2 2 084 770 en Operating instructions for lattice extension GMK 5100...
Page 167 Index Auxiliary single-sheave boom top installing/removing ......5-3 possible reeving methods ..... . . 5-3 rigging .
Page 168 Heavy load lattice extension lowering in working position heavy load lattice extension ..... 6-13 Hoist cable positioning/removing on lattice extension ... . . 3-52 positioning/removing on the boom extension .
Page 169 Rigging the heavy load lattice extension ... . . 6-9 – 6-18 Run-up rail folding out/in ......3-32 set .
Page 170 Blank page Alphabetical index - 6 2 084 770 en Operating instructions for lattice extension GMK 5100...

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