Page 1 Lattice extension operating instructions 3 112 319 en Serial number 08.09.2006...
Page 2 Important note Duplications of any kind and excerpts from this document are not subject to the revision service. Original documents of Deutsche GROVE GmbH are marked with the blue serial number of the truck crane on the cover sheet. Duplications and printouts of data carriers on which Deutsche GROVE GmbH has delivered this document are also not subject to the revision service.
Page 3 Setting the angle position of the heavy load lattice extension In section 6.4.3 in paragraph Setting the angle 0° angle position the texts (1) and (2) have been as- (transport position) signed to the illustrations incorrectly. The text next to the illustration is correct. 30°...
Page 4 Blank page 3 113 050 en Correction sheet GMK 5220...
Page 5 These operating instructions contain the following chapters: Important information Transport dimensions and weights 12/21 m (39/69 ft) swing-away lattice extension Boom extension Auxiliary single-sheave boom top Heavy load lattice extension Index Lattice extension operating instructions 3 112 319 en GMK 5220...
Page 6 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 7: Table Of Contents
Important information About these operating instructions........1 - Basic safety instructions .
Page 8 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 9: Important Information
Prerequisites for The lattice extensions described in these operating instructions may only be assembly and operated together with the GROVE GMK 5220 truck crane whose serial operation number is identical with the serial number marked on the lattice extensions. Safetyinstructions...
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 instruc- tions to highlight particularly important information: This symbol indicates hazards related to the operation described which may cause personal injury.
Page 11: Intended Use
Important information 1.3 Intended use Intended use The GMK 5220 truck crane is constructed in accordance with the latest tech- nology 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 Intended 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 mechanism –...
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 removed from the truck crane. You must have read and understood the operation and safety instructions in these operating instructions, and comply with them when working.
Page 14 Important information 1.4 Organizational measures Ensure that all safety and warning signs on the truck crane remain legible. Note the operational organization on the site. Report your arrival to site management. Ask for the employee authorized to instruct you. Familiarize yourself with the location and operation of the fire extinguishers on every site.
Page 15: Personnel Qualifications
Important information 1.5 Personnel qualifications Personnel qualifications These operating instructions are not a training manual for prospective crane operators. All descriptions are written explicitly for crane operators who have been trained to operate truck cranes. Employees in training may only operate the truck crane under strict super- vision.
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 work safely. Check over the truck crane before beginning crane work. Check the condi- tion of the truck crane carefully using the checklists in the operating instruc- tions.
Page 17 Important information 1.6 Safety instructions for truck crane work Before turning the superstructure, support the truck crane with the outrig- ger span required for the currently rigged counterweight. Ensure that the truck crane is horizontally aligned before carrying out crane work.
Page 18: Specifications In Us Standard Units Of Measurement
Important information 1.7 Specifications in US standard units of measurement Specifications in US standard units of measurement In these operating instructions, the lattice extension lengths are given in metric units and US standard units of measurement. The values for the US standard units are rounded to the nearest whole number.
Page 19 Transport dimensions and weights Swing-away lattice extension ......... 2 - Auxiliary single-sheave boom top .
Page 20 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 21 Transport dimensions and weights 2.1 Swing-away lattice extension Transport dimensions and weights Swing-away lattice extension Length x width x height Weight in kg Description in m (ft) (lbs) 21 m (69 ft) swing-away lattice 12.7 x 1.1 x 1.5 2 010 extension, complete, folded (42.0 x 3.6 x 5.0) (4 430)
Page 22 Transport dimensions and weights 2.2 Auxiliary single-sheave boom top Auxiliary single-sheave boom top Description Length x width x Weight in kg (lbs) height in m (ft) Auxiliary single-sheave boom 1.1 x 0.9 x 1.0 (3.6 x 3.0 x 3.3) (135) top complete with pins Heavy load lattice extension Description...
Page 23 12/21 m (39/69 ft) swing-away lattice extension Additional operating and display elements ......3 - 3.1.1 In the crane cab .
Page 24 Operation with the lattice extension........3 - 95 3.7.1 Setting.
Page 25: Additional Operating And Display Elements
12/21 m (39/69 ft) swing-away lattice extension 3.1 Additional operating and display elements 12/21 m (39/69 ft) swing-away lattice extension Additional operating and display elements When the GMK 5220 is equipped with swing-away lattice extension, certain operating and display elements in the crane cab also apply to the operation of the lattice extension.
Page 26 12/21 m (39/69 ft) swing-away lattice extension 3.1 Additional operating and display elements To switch on derricking gear: Indicator lamp is dimly lit. Press rocker button upwards once; the indicator lamp will then be brightly lit. If the control lever is assigned more than one function, all other power units which are assigned the same movement of the control lever are switched off.
Page 27 12/21 m (39/69 ft) swing-away lattice extension 3.1 Additional operating and display elements On the crane Various indicators and adjustment capabilities become active on the control display hydraulically derricked lattice extension. For calling up menus and for set- à Operating instructions GMK 5220 – Part 2 Crane operation . ting If the electrical connection between the main boom and the lattice extension is disconnected, the symbol for the lattice extension will be shown in grey...
Page 28 12/21 m (39/69 ft) swing-away lattice extension 3.1 Additional operating and display elements – Boom system • Press the button (4) repeatedly until the symbol for the required input is green. 1 Boom system input 2 Lattice extension length/angle input •...
Page 29: Operating And Display Elements On The Hand-Held Control
12/21 m (39/69 ft) swing-away lattice extension 3.1 Additional operating and display elements 3.1.2 Operating and display elements on the hand-held control à Connection options for hand-held control; With the hand-held control , p. 3 - 91. If a hydraulically derricked lattice extension is electrically connected, the Derrick lattice extension (1) pre-selection button will become active.
Page 30: Operating And Display Instruments On The Swing-Away Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.1 Additional operating and display elements 3.1.3 Operating and display instruments on the swing-away lattice extension There is a button unit with two buttons on the front of section 1. 1 “Raise lattice extension” push-button 2 “Lower lattice extension”...
Page 31: Identification Of The Swing-Away Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.2 Identification of the swing-away lattice extension Identification of the swing-away lattice extension The swing-away lattice extension is designed for the truck crane with which it was delivered. The sections of the swing-away lattice extension belonging to the truck crane have the same serial number as the truck crane.
Page 32 12/21 m (39/69 ft) swing-away lattice extension 3.2 Identification of the swing-away lattice extension Serial number Section 1 consists of a fixed section and an inclinable section. on section 1 On the inclinable section the serial number (1) is at the front on a plate to the right of the deflection sheave.
Page 33: Composition Of The Swing-Away Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.3 Composition of the swing-away lattice extension Composition of the swing-away lattice extension 12 m (39 ft) swing-away lattice extension Section 1 (12 m (39 ft)) 21 m (69 ft) swing-away lattice extension Section 2 (9 m (30 ft)) Section 1 (12 m (39 ft)) The length data for the swing-away lattice extension of 12 m (39 ft) and 21 m...
Page 34: Centres Of Gravity For Slinging
12/21 m (39/69 ft) swing-away lattice extension 3.4 Centres of gravity for slinging Centres of gravity for slinging When you sling the lattice extension or an component, then you have to observe the different centres of gravity so that the sections hang horizon- tally.
Page 35: Checklists For Rigging Work
12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work Checklists for rigging work 3.5.1 Overview of the required rigging work There are different initial states for rigging the lattice extension, depending on whether – the lattice extension is folded at the side of the main boom or –...
Page 36: Checklist: Installing The 12/21 M (39/69 Ft) Swing-Away Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 3.5.2 CHECKLIST: Installing the 12/21 m (39/69 ft) 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.
Page 37 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work Danger of becoming trapped due to swinging lattice extension. Always secure the lattice extension against swinging with the auxiliary crane and the guide ropes before you establish the hydraulic or electrical connection.
Page 38 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 3.5.3 CHECKLIST: Removing the 12/21 m (39/69 ft) 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.
Page 39 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work à 4. Slinging the lattice extension to the auxiliary crane; Centres of gravity for slinging , p. 3 - 10. 5. Remove the connection on the right and left between the main boom à...
Page 40 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work For a folded lattice This checklist only applies when the lattice extension is folded at the extension side of the main boom. When the lattice extension is rigged, another à...
Page 41 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 6. When the 21 m (69 ft) swing-away lattice extension is folded to the side: – Disconnect the connection between section 2 and the main boom in à the Rear area;...
Page 42 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work Blank page 3 - 18 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 43: Checklist: Rigging The 12/21 M (39/69 Ft) Swing-Away Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 3.5.4 CHECKLIST: Rigging the 12/21 m (39/69 ft) swing-away lattice extension This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by cross-refer- ences.
Page 44 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work à 6. Fold out the run-up rail; p. 3 - 45. 7. Secure the lattice extension on the main boom with guide rope; à Securing the lattice extension with rope , p. 3 - 32. 8.
Page 45 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 11. This point only applies when rigging the 21 m (69 ft) swing-away lattice extension. – Check that the connection in the middle area is in the position à...
Page 46 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 17. In the front area, move the connection into the unrigging position; à Moving the Front connection into the Unrigging position , p. 3 - 50. When the 12 m (39 ft) swing-away lattice extension is rigged – proceed as à...
Page 47 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 23. Establish electrical connection between section 1 and section 2; à Establishing the electrical connection , p. 3 - 76. à Folding out the deflec- 24. Fold out both deflection sheaves on section 1; tion sheaves , p.
Page 48 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 29. Attach the lifting limit switch weight and place it around the hoist rope; à Operating instructions GMK 5220, Part 2 Superstructure – Rigging work. 30. Check the alignment of the truck crane and, if necessary, position the truck crane so that it is level.
Page 49 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 3.5.5 CHECKLIST: Unrigging the 12/21 m (39/69 ft) swing-away lattice extension This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by cross- references.
Page 50 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work à 7. Remove the anemometer; Installing/removing the anemometer , p. 3 - 85. à Folding in the deflection 8. Fold in both deflection sheaves on section 1; sheaves , p. 3 - 79. 9.
Page 51 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 12. If section 2 is to be removed: – Sling section 2 onto the auxiliary crane, centre of gravity; à p. 3 - 10. – Remove the locking pins between section 2 and section 1; à...
Page 52 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 18. Release the connection between section 1 and the main boom head at à Releasing connections , the left and right of the main boom head; p. 3 - 61. 19.
Page 53 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 24. This point only applies to the unrigging of the 12 m (39 ft) swing-away lattice extension, when only section 1 is installed. Release the connection between section 1 and the main boom in the à...
Page 54 12/21 m (39/69 ft) swing-away lattice extension 3.5 Checklists for rigging work 30. Check whether the lattice extension is in transport condition; à For a folded lattice extension , p. 3 - 16. 31. Put the hydraulic hoses into the correct position for working with the main boom, or remove the hose drum if necessary: –...
Page 55: Description Of Rigging Work
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Description of rigging work 3.6.1 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 the following prerequisites are met, lowering into the horizontal position with lattice extension/boom extension and a slewing range of 360°...
Page 56 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work – All telescopic sections must be completely retracted. – The SLI code for operation with the rigged lattice extension must have been entered. Securing the lat- If the truck crane is not well aligned, the lattice extension may swing out of tice extension its own accord when you remove the last connection that held the lattice with rope...
Page 57: Checking The Transport Condition
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.2 Checking the transport condition For transportation you must establish certain connections between both sections of the lattice extension. The connections which need to be estab- lished depend on whether the lattice extension: –...
Page 58 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Transport condi- The transport condition with the lattice extension folded at the side is cre- tion with lattice ated when all of the following connections are established. extension folded at the side When section 1 and section 2 are folded to the side •...
Page 59 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Only when section 1 is folded to the side: • Check the following connections and establish them if necessary: – In the Front area, section 1 must be engaged at the slewing axis (2) on the main boom and the slewing axis must be secured with the pin (3);...
Page 60 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Only when section 2 is folded to the side: • Check the following connections and establish them if necessary: – In the middle area, the connection (4) is in the position section 2/main à...
Page 61 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Transport condi- The transport condition for the removed lattice extension is established tion with removed when all of the following connections have been made. lattice extension • Check the following connections and establish them if necessary. –...
Page 62: Checking The Locking Device On The Hose Drum
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.3 Checking the locking device on the hose drum A hose drum on the left hand side of the main boom provides the hydraulic supply. The hosedrum is equipped with an locking device. The locking device is only needed for installing and removing the hose drum.
Page 63 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Inserting the If the hose drum has to be removed, you have to insert the locking device locking device beforehand. Risk of accidents from uncontrolled turning of hose drum The locking device always has to be inserted before the hose drum is removed.
Page 64 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Risk of accidents from hydraulic hoses springing back If you detach the strain relief after the locking device has been released, do not under any circumstances let go of the strain relief before it has been re- attached.
Page 65: Installing/Removing The Hose Drum
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.4 Installing/removing the hose drum Installing the hose drum • (A) – Attach the hose drum (1) to a reservoir. • Pull the pins (2) out of the holder. •...
Page 66 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Removing the Depending on the driving mode of the truck crane the hose drum must be hose drum removed for on-road driving with a maximum axle load of 12 t (26 500 lbs); à...
Page 67: Establishing/Disconnecting The Hydraulic Connection
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.5 Establishing/disconnecting the hydraulic connection Establishing the hydraulic connection • If necessary, bring the connections (1) into the position for working with the lattice à extension; p. 3 - 40. •...
Page 68 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Blank page 3 - 44 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 69: Folding The Run-Up Rail Out/In
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.6 Folding the run-up rail out/in The run-up rail is folded out for rigging and folded back in for on-road driv- ing after unrigging. Folding out the run-up rail •...
Page 70: Connections With Folded Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.7 Connections with folded lattice extension The lattice extension is swung to the side of the main boom in the folded up position. In this position there are four areas on the main boom basic section, where various connections have to be disconnected and reconnected again during rigging and unrigging: 1 Front area, in front of the locking point at 100%...
Page 71 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Establishing a connection To establish a connection, the lattice exten- sion must be on the run-up rail. • Check if the pin (4) is pulled out of the bore hole (3).
Page 72 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Releasing the connection à • Check that the connection has been made; p. 3 - 58. à • Secure the lattice extension with a guide rope; p. 3 - 32. –...
Page 73 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work • Withdraw the pin (4) from the bore (3) and insert it into the holder (5). • Secure the pin (4) using the retaining pin. You can now retract the slewing axis (1) so that it no longer protrudes from the holder (2).
Page 74 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Moving the Front connection into the Unrigging position Before you fold the lattice extension onto the side during unrigging, the Front connection must be moved into the Unrigging position. Danger of becoming trapped due to swinging lattice extension Start the subsequent work only if the lattice extension is locked in front of the main boom head or it is secured against swinging around.
Page 75 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Connections in the The connection in the Middle area consists of a locking bar with two pins. middle area Depending on the position of the locking bar, different sections are con- nected with one another.
Page 76 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Establishing the position Section 2/ main boom This position must be established in the fol- lowing circumstances: – when unrigging the 12 m (39 ft) swing-away lattice extension – when section 2 is installed.
Page 77 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Connections in In the Rear area there are three different connections: the rear area – the connection between section 2 and the main boom – the connection between section 1 and the main boom –...
Page 78 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Releasing the connection – with a 21 m (69 ft) lattice extension • Before releasing the connection, check that à – the connection is established in the Front area; p.
Page 79 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work • Loosen the retaining pin and remove the bolt (2) from the connecting point (3). • Insert the pin into the retaining sheet (1). • Secure the pin with the retaining pin. Connection between section 1 and the main boom This connection does not apply to truck cranes that are supplied with a 21 m (69 ft).
Page 80 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Releasing the connection à • Check if the connection is made in the Front area; p. 3 - 47. Risk of accidents through section 1 falling down Check that the connection is made in the Front area. This will prevent section 1 from falling down when this connection is released.
Page 81 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Establishing a connection • Remove the retaining pins and pull the con- ical pin (4) and another pin (2) out of the retaining sheet (1). • Insert the pin (2) into the upper connecting point (3).
Page 82: Connecting/Disconnecting The Slewing Connection
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.8 Connecting/disconnecting the slewing connection The slewing connection is created on the right of the main boom head using two pins. The pins required can be found in the holders at the rear of section 1.
Page 83 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Releasing a slew- The connection must be released after the lattice extension is swivelled ing connection onto the main boom side and pinned there during unrigging. Risk of accidents from a falling lattice extension When the lattice extension is folded to the side, make sure that all the con- nections are created as stipulated according to CHECKLIST: Unrigging the 12/21 m (39/69 ft) swing-away lattice extension for the lattice extension cur-...
Page 84: Connections On The Left And Right Of The Main Boom Head
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.9 Connections on the left and right of the main boom head The connections on the right and left on the main boom head are made using pins. The pins required can be found in the holders at the rear of section 1.
Page 85 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Right-hand connections • Remove the retaining pins and pull the pins (2) out of the holder (1). • Insert the pins into the connecting points (3). • Secure the pins using the retaining pins. Releasing The connections must be released so that the lattice extension can be connections...
Page 86 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Right-hand connection The pins (4) for the slewing connection must remain inserted! • Remove the retaining pins and pull the pins (2) out of the connecting points (3). •...
Page 87 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Relieving the The dead weight of the lattice extension can cause misalignment of the connecting points bearing points, and can also weight down the pins and make it impossible to knock them out.
Page 88: Swinging The Lattice Extension Onto The Main Boom Head
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.10 Swinging the lattice extension onto the main boom head This section describes slewing the lattice extension – onto the main boom head when rigging and – onto the main boom basic section when removing. The lattice extension must be swung out of the transport position onto the main boom head so that section 1 can be fastened to the right side of the main boom head with pins.
Page 89: Swinging The Lattice Extension When Rigging
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.11 Swinging the lattice extension when rigging When rigging – When rigging the 12 m (39 ft) or 21 m (69 ft) swing-away lattice extension, section 1 you must swing section 1 in front of the main boom head. •...
Page 90 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work When unrigging – When unrigging the 12 m (39 ft) or 21 m (69 ft) swing-away lattice extension, section 1 you must swing section 1 to the side of the main boom. Risk of accidents from lattice extension swinging of its own accord Always secure the lattice extension with a guide rope before swinging it.
Page 91 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work When rigging – When rigging the 21 m (59 ft) swing-away lattice extension, you must swing section 2 section 2 in front of section 1 as well. Risk of accidents through section 2 swinging of its own accord Always secure section 2 with a guide rope before you release the connec- tion between section 1 and section 2 and only position the ladder on the left at section 1.
Page 92 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work When unrigging – When unrigging the 21 m (69 ft) swing-away lattice extension, you must section 2 swing section 2 to the side of section 1. Check that the electrical connection between section 1 and section 2 is bro- ken before you swing section 2 towards section 1.
Page 93: Establishing/Releasing Connections On The Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.12 Establishing/releasing connections on the lattice extension The procedure for establishing and releasing the connections between section 1 and section 2 depends on the transport condition of the sections. –...
Page 94 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Section 1 and This section presupposes that section 1 and section 2 are folded up on the section 2 installed side of the main boom for transportation. Risk of accidents through section 2 swinging of its own accord Always secure section 2 with a guide rope and only position the ladder on the left of section 1.
Page 95 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Releasing the connection The connection is released before section 2 is folded onto the side of section 1. • Loosen the retaining pin and remove the pin (2) from the connecting point (3). •...
Page 96 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Only section 1 This section presupposes that section 1 is folded up on the side of the main installed boom and section 2 is removed for transportation. Danger of crushing by swinging section 2 Always secure section 2 with a guide rope from the ground before estab- lishing or releasing the connection.
Page 97 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Releasing the connection • Sling section 2 onto an auxiliary crane, cen- à tre of gravity; p. 3 - 10. • Remove the retaining pins and pull the pins (2) out of the connecting points (3) on both sides.
Page 98: Electrical Connections On The Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.13 Electrical connections on the lattice extension The SLI, the lifting limit switch and the anemometer are connected via the electrical connection on the lattice extension. Danger of becoming trapped due to swinging lattice extension Start the subsequent work only if the lattice extension is locked in front of the main boom head or it is secured against swinging around.
Page 99 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Disconnecting the electrical connection • Remove the plug (4) from the socket (3) and plug it into the dummy socket (6). • Wind the cable (5) onto the holder (7). •...
Page 100 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work On 21 m (69 ft)- For the 21 m (69 ft) swing-away lattice extension, a further connection must swing-away lat- be established or released between section 1 and section 2 in addition to tice extension that made for the electrical connection of the 12 m (39 ft) swing-away lattice extension.
Page 101: Folding Deflection Sheave Out/In
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.14 Folding deflection sheave out/in To prevent the hoist rope dragging on the main boom or lattice extension during operation with the lattice extension or boom extension, the hoist rope is guided via deflection sheaves.
Page 102 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Front deflection sheave • (A) – Unscrew the retaining pin from the pin (2). • Hold the deflection sheave by the strut (1) and pull out the pin (2). •...
Page 103 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Folding in the For transportation you must fold in the deflection sheaves. deflection sheaves Danger of accidents by exceeding the permitted overall height! Always fold in the deflection sheave when the lattice extension is folded onto the side of the main boom for driving.
Page 104: Positioning/Removing The Hoist Rope
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.15 Positioning/removing the hoist rope Risk of accidents due to falling parts Always secure the hoist rope holding rollers and rods with retaining pins. This prevents elements from coming loose, falling down and injuring peo- ple.
Page 105 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Possible reeving The hoist rope can be reeved a maximum of two falls on the 12 m (39 ft) methods on the swing-away lattice extension. lattice extension The hoist rope can be reeved only one fall on the 21 m (69 ft) swing-away lattice extension and on the boom extension.
Page 106: Installing/Removing The Lifting Limit Switch
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.16 Installing/removing the lifting limit switch The functions Raise hoist, Extend main boom , Lower main boom and, with hydraulically derricked lattice extension, Derrick lattice extension are moni- tored 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 107 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work On 12 m (39 ft) swing-away lat- tice extension Connecting the lifting limit switch • Release the retaining pin (5) and place the holder with the lifting limit switch (6) on the grip (4) on section 1.
Page 108 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work On 21 m (69 ft) This section also applies when the boom extension is rigged. swing-away lat- tice extension Connecting the lifting limit switch • Loosen the retaining pin (4) and place the holder with the lifting limit switch (5) on the grip (3) on section 2.
Page 109: Installing/Removing The Anemometer
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.17 Installing/removing the anemometer On 12 m (39 ft) The anemometer is mounted on a grip. swing-away lat- tice extension Mounting the anemometer • Loosen the retaining pin (1). •...
Page 110 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Removing the anemometer • Pull the plug of the anemometer from the socket (4). • Cover the socket (4) with the protective cap. • Loosen the retaining pin (1). •...
Page 111 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work On 21 m (69 ft) This section also applies when the boom extension is rigged. swing-away lattice extension Mounting the anemometer • Loosen the retaining pin (1). • Insert the grip (3) into the holder (2).
Page 112 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Removing the anemometer • Pull the plug of the anemometer from the socket (4). • Cover the socket (4) with the protective cap. • Loosen the retaining pin (1). •...
Page 113: Air Traffic Control Light - Electrical Connection
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.18 Air traffic control light – electrical connection The air traffic control light (additional equipment) is mounted on the grip of the anemometer. Establishing the electrical connection On 12 m (39 ft) swing-away lattice extension: à...
Page 114 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work Disconnecting the electrical connec- tion • Switch off the air traffic control light by pressing the top part of the Air traffic control light on/off rocker switch. On 12 m (39 ft) swing-away lattice extension: •...
Page 115: Derricking The Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.19 Derricking the lattice extension • Before derricking the lattice extension, enter an SLI code for working with à Setting , the lattice extension so that derricking will be enabled; p.
Page 116 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work • Wait until the CAN (2) and Charge control (1) indicator lamps go on. There is a malfunction if the CAN indicator lamp does not go on after à...
Page 117 12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work During operation During operation the lattice extension is derricked from the crane cab. The lattice extension can be derricked only when the derricking gear for the lattice extension is switched on. After turning on the ignition, all power units are switched off and the indi- cator lamps in the corresponding rocker buttons light up dimly.
Page 118: Transportation On A Separate Vehicle
12/21 m (39/69 ft) swing-away lattice extension 3.6 Description of rigging work 3.6.20 Transportation on a separate vehicle Risk of accidents from a falling lattice extension 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 capacity.
Page 119: Operation With The Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.7 Operation with the lattice extension Operation with the lattice extension When operating the lattice extension, the maximum speed for the different à Operating instructions GMK 5220 – Crane power units is limited to 70%, operation –...
Page 120: Setting
12/21 m (39/69 ft) swing-away lattice extension 3.7 Operation with the lattice extension 3.7.1 Setting If a hook block is reeved on the main boom during operation with the lattice extension, the loads given in the Lifting capacity tables decrease and the SLI subsequently switches off earlier.
Page 121 12/21 m (39/69 ft) swing-away lattice extension 3.7 Operation with the lattice extension the load according to the Lifting capacity table and the Maximum load display (1) shows the corresponding value. Only the value for the empty hook curve is released and shown when the telescopic sections are unlocked.
Page 122: Raising And Setting Down The Main Boom
12/21 m (39/69 ft) swing-away lattice extension 3.7 Operation with the lattice extension 3.7.2 Raising and setting down the main boom The information in this section also applies for raising and setting down the main boom with a rigged boom extension. The following prerequisites must be fulfilled when raising and setting down the main boom: –...
Page 123: Telescoping With Rigged Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.7 Operation with the lattice extension 3.7.3 Telescoping with rigged lattice extension Risk of overloading the main boom 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 being subjected to additional side forces and increased vibration and becoming overloaded.
Page 124: Information About The Sli Shutdown
12/21 m (39/69 ft) swing-away lattice extension 3.7 Operation with the lattice extension 3.7.4 Information about the SLI shutdown The information in this section also applies to operation with the boom extension. Operation with the lattice extension is monitored by the SLI. SLI shutdowns can occur during operation with the lattice extension for the same reasons as shutdowns occurring during operation with the main à...
Page 125: Procedure If The Permissible Wind Speed Is Exceeded
12/21 m (39/69 ft) swing-away lattice extension 3.7 Operation with the lattice extension 3.7.5 Procedure if the permissible wind speed is exceeded Strong winds lead to the truck crane being overloaded. For this reason, closely observe the instructions contained in the the Section Effect of wind on à...
Page 126: Information About The Main Boom Operation When The Lattice Extension Is
12/21 m (39/69 ft) swing-away lattice extension 3.7 Operation with the lattice extension 3.7.6 Information about the main boom operation when the lattice extension is folded/rigged Folded This section applies when the lattice extension is folded at the side. If a lattice extension is folded at the side during operation with the main boom, the loads given in the Lifting capacity tables decrease.
Page 127 12/21 m (39/69 ft) swing-away lattice extension 3.7 Operation with the lattice extension In the Lifting capacity tables you will find tables with values for the reduction of the lifting capacities in the Section Remarks about working with the swing- away lattice extension .
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Page 129: Turning Loads With The Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.8 Turning loads with the lattice extension Turning loads with the lattice extension Two-hook operation is required for turning loads. 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. Risk of accidents due to overloading Lifting a load with two hooks is permissible only if the following instruc- tions and illustrations are observed.
Page 130: Setting The Sli
12/21 m (39/69 ft) swing-away lattice extension 3.8 Turning loads with the lattice extension 3.8.2 Setting the SLI You must enter the following settings on the SLI for two-hook operation: – Enter the current reeving for the main and auxiliary hoist. The values are stored and called up directly when switching hoists.
Page 131 12/21 m (39/69 ft) swing-away lattice extension 3.8 Turning loads with the lattice extension Setting the SLI to The SLI always takes into account the reeving entered for the hoist which is displayed at the Hoists indicator lamps. For turning loads, the SLI must take the auxiliary hoist the auxiliary hoist and its reeving into account and both hoists must be switched on.
Page 132: Turning A Load
12/21 m (39/69 ft) swing-away lattice extension 3.8 Turning loads with the lattice extension 3.8.3 Turning a load Carry out the load turning only as it is described in this section. Risk of accidents due to overloading Keep the acceleration forces as low as possible during two-hook operation. For this reason, move the load at the lowest possible speed! If the load is on two hooks, there will be slight differences in the Current load display.
Page 133 12/21 m (39/69 ft) swing-away lattice extension 3.8 Turning loads with the lattice extension • Now lift the load with the hook block on the main boom until both slinging points are at the same height. • Slacken the hoist rope on the lattice exten- sion until the load is only hanging from the hook block on the main boom.
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Page 135: Driving With Rigged Truck Crane And Rigged Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension Driving with rigged truck crane and rigged lattice extension This section describes how you can move the truck crane with an installed counterweight and rigged lattice extension (e.g. when the lattice extension cannot be rigged on the site due to lack of space).
Page 136: Driving Route
12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension 3.9.1 Driving route The route must be along a flat, even surface. The level adjustment system cannot compensate for uneven surfaces. If the surface pressure of the tyres exceeds the permissible load on the ground, the bearing surface pressure must be increased using packing made of durable material (e.g.
Page 137 12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension 3.9.2 Boom positions and axle loads The truck crane may only be moved under certain circumstances. The main boom and the lattice extension must be moved to specified positions, depending on the counterweight installed.
Page 138: 3.9 Driving With Rigged Truck Crane And Rigged Lattice Extension
12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension 12 m (39 ft) swing- All the axle loads in the following table apply for a 32 t hook block (weight awaylattice exten- 600 kg (1320 lbs)) reeved on the lattice extension.
Page 139 12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension 21 m (69 ft) swing- All the axle loads in the following table apply for hook tackle (weight 300 kg awaylattice exten- (660 lbs)) reeved on the lattice extension. sion The maximum axle load specified in the table is reached at a main boom angle of either x°...
Page 140: Driving The Rigged Crane
12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension 3.9.3 Driving the rigged crane Closing the slew- ing gear brake ç • Switch the slewing gear off; to do this, press the Slewing gear on/off rocker button up once.
Page 141 12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension Switching over Operation is carried out on the Driver's cab display, in the Level adjustment à system submenu; Operating instructions GMK 5220 – Part 1 Driving – Sus- suspension pension .
Page 142 12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension Switching on sep- Before driving with the rigged crane you must switch on separate steering: arate steering Risk of damaging the steering linkage Before driving the rigged crane always switch on separate steering.
Page 143 12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension Please observe the following points when driving: • Drive as slowly as possible. • The turning radius should be as large as possible when driving around corners.
Page 144 12/21 m (39/69 ft) swing-away lattice extension 3.9 Driving with rigged truck crane and rigged lattice extension • Turn on the suspension. To do so, press the button next to the Suspension on/off symbol once (2). The Suspension display (1) shows the green symbol for Suspension on . •...
Page 145: Finding And Eliminating Malfunctions
12/21 m (39/69 ft) swing-away lattice extension 3.10 Finding and eliminating malfunctions 3.10 Finding and eliminating malfunctions Malfunction Cause Remedy Lifting limit switch not func- Lifting limit switch not con- Connect the lifting limit à tioning nected switch; p. 3 - 82. The connection for the lifting Override the lifting limit limit switch on the main boom...
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Page 147: Maintenance Work
12/21 m (39/69 ft) swing-away lattice extension 3.11 Maintenance work 3.11 Maintenance work 3.11.1 Modules in need of protection during cleaning work • Provide protection for the following electrical parts during cleaning work: 1 the differential angle indicator on section 1 2 the control box at the rear of section 1 3 the control box at the front of section 1 4 the control box at the front of section 2...
Page 148: Maintenance Work M1, Monthly
12/21 m (39/69 ft) swing-away lattice extension 3.11 Maintenance work 3.11.2 Maintenance work M1, monthly For lubricating the pins and support rollers, use the same grease as stated in the Maintenance manual as for connecting pins and socket pins; à Maintenance manual GMK 5220 Maintenance overview –...
Page 149: Maintenance Work M12, Every Twelve Months
12/21 m (39/69 ft) swing-away lattice extension 3.11 Maintenance work 3.11.3 Maintenance work M12, every twelve months Lubricate joints The joints in section 1 are lubricated via lubricating nipples. on section 1 In section 1 there is one lubricating nipple (1) in the pivot point.
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Page 151 Boom extension Identification and slinging points ........4 - 4.1.1 Identification.
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Page 153: Boom Extension
Boom extension 4.1 Identification and slinging points Boom extension Identification and slinging points 4.1.1 Identification The boom extension consists of the 21 m (69 ft) swing-away lattice exten- sion and two boom extension sections. The boom extension is designed for the truck crane it was delivered with.
Page 154: Slinging Points
Boom extension 4.1 Identification and slinging points Serial numbers on section 3 and section 4 On section 3 and section 4, the serial number (1) is at the front on a plate. 4.1.2 Slinging points Risk of accidents due to falling lattice extension sections Only sling section 3 and section 4 at the slinging points provided.
Page 155: Assembly Of Boom Extensions
Boom extension 4.2 Assembly of boom extensions Assembly of boom extensions Risk of accidents from incorrect assembly Assemble the boom extension as shown here. Section 3 must always be bolted to the deflection sheave on the main boom head. When section 4 is bolted to the main boom head, the hoist rope rubs and may be damaged.
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Page 157: Checklists For Rigging Work
Boom extension 4.3 Checklists for rigging work Checklists for rigging work 4.3.1 CHECKLIST: Rigging the 29/37 m (95/121 ft) 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 instructions given there. Prerequisites: –...
Page 158 Boom extension 4.3 Checklists for rigging work 6. Sling the necessary sections onto the auxiliary crane one after the other and install in front of the main boom: – For 29 m (95 ft) boom extension section 3, – For 37 m (121 ft) boom extension, first section 3 and then section 4; à...
Page 159 Boom extension 4.3 Checklists for rigging work 12. Establish the connection on the left between section 2 and section 1; à p. 3 - 70. 13. In the case of the the hydraulically derricked lattice extension, establish the hydraulic connection; à...
Page 160: 22. Enter Sli Code According To The Lifting Capacity Table For The Actual Rigging
Boom extension 4.3 Checklists for rigging work à 18. Install the lifting limit switch; On 21 m (69 ft) swing-away lattice exten- sion , p. 3 - 84. à Positioning/removing the hoist rope , p. 4 - 27. 19. Reeve the hoist rope; 20.
Page 161: Checklist: Unrigging The 26/32 M (85/121 Ft) Boom Extension
Boom extension 4.3 Checklists for rigging work 4.3.2 CHECKLIST: Unrigging the 26/32 m (85/121 ft) 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 instructions given there. Prerequisites: –...
Page 162 Boom extension 4.3 Checklists for rigging work 6. Reeve out hoist rope from the hook block. à Positioning/removing the 7. Reel hoist rope up to the main boom head; hoist rope , p. 4 - 27. à Removing the anemometer , p. 3 - 88. 8.
Page 163 Boom extension 4.3 Checklists for rigging work 12. Fasten the guide ropes to the front of section 2. 13. If section 2 is to be removed: – Sling section 2 onto the auxiliary crane, centre of gravity; à p. 3 - 10. –...
Page 164 Boom extension 4.3 Checklists for rigging work à 18. Remove the folded swing-away lattice extension; Dismantling , p. 4 - 17. 19. Sling the rigged sections onto the auxiliary crane and remove from the main boom: – For 29 m (95 ft) boom extension section 3, –...
Page 165: Description Of Rigging Work
Boom extension 4.4 Description of rigging work Description of rigging work 4.4.1 Installing/dismantling section 3 and section 4 Installing For the 29 m (95 ft) boom extension, you only need to install section 3. For the 37 m (121 ft) boom extension, you first need to install section 3 and then section 4.
Page 166 Boom extension 4.4 Description of rigging work Dismantling For the 37 m (121 ft) boom extension, you first need to dismantle section 4 and then section 3. For the 29 m (95 ft) boom extension, you only need to dismantle section 3. Risk of damage to connection cables and hydraulic hoses Before dismantling, ensure that the electric and hydraulic connections have been cut.
Page 167: Installing/Dismantling The Lattice Extension For The Boom Extension
Boom extension 4.4 Description of rigging work 4.4.2 Installing/dismantling the lattice extension for the boom extension This section describes the installation and dismantling of the folded lattice extension. You may also install the folded up lattice extension in front of section 3 or section 4 (e.g.
Page 168 Boom extension 4.4 Description of rigging work Dismantling When unrigging, you must dismantle the lattice extension. Risk of damage to connection cables and hydraulic hoses Before dismantling, ensure that the electric and hydraulic connections have been cut. This prevents damage to the connection cable and the hydraulic hoses dur- ing dismantling.
Page 169: Hydraulic Connection At The Boom Extension
Boom extension 4.4 Description of rigging work 4.4.3 Hydraulic connection at the boom extension On the 29 m (95 ft) All connections are made via quick-action couplings. The correct allocation boom extension is given using different forms and sizes. Establishing a connection •...
Page 170 Boom extension 4.4 Description of rigging work Disconnecting • (A) – Disconnect the hose lines (2) from the connections (1). • Close the hose lines and the connections with the protective caps. • Guide the hose lines (2) into section 3 and place them on the lower cross-strut.
Page 171 Boom extension 4.4 Description of rigging work On the 37 m All connections are made via quick-action couplings. The correct allocation (121 ft) boom is given using different forms and sizes. extension Establishing a connection • (A) – If necessary, bring the connections (1) on the left side of the main boom head into the position for working with the lattice à...
Page 172 Boom extension 4.4 Description of rigging work Disconnecting • (A) – Disconnect the hose lines (2) from the connections (1). • Close the hose lines and the connections with the protective caps. • Guide the hose lines (2) into section 3 and place them on the lower cross-strut.
Page 173: Electrical Connection At The Boom Extension
Boom extension 4.4 Description of rigging work 4.4.4 Electrical connection at the boom extension On the 29 m (95 ft) boom extension Establishing a connection • (A) – Remove the bridging plug (1) from the socket (3) and insert it into the dummy socket (2).
Page 174 Boom extension 4.4 Description of rigging work Disconnecting • (A) – Remove the plug (4) from the socket (3) and insert it into the dummy socket (6). • Wind the cable (5) onto the holder (7). • Remove the bridging plug (2) from the dummy socket (1) and plug it into the socket (3).
Page 175 Boom extension 4.4 Description of rigging work On the 37 m (121 ft) boom extension Establishing a connection • (A) – Remove the bridging plug (1) from the socket (3) and insert it into the dummy socket (2). • Unwind the cable (5) from the holder (6). •...
Page 176 Boom extension 4.4 Description of rigging work Disconnecting • (A) – Remove the plug (4) from the socket (3) and insert it into the dummy socket (6). • Wind the cable (5) onto the holder (7). • Remove the bridging plug (2) from the dummy socket (1) and plug it into the socket (3).
Page 177: Fold In/Fold Out The Deflection Sheave On Section 3
Boom extension 4.4 Description of rigging work 4.4.5 Fold in/fold out the deflection sheave on section 3 This section describes only the folding in and out of the deflection sheave in section 3. For folding the deflection sheaves on section 1 in and out; à...
Page 178: Positioning/Removing The Hoist Rope
Boom extension 4.4 Description of rigging work 4.4.6 Positioning/removing the hoist rope Risk of accidents due to falling parts Always secure the hoist rope holding rollers and rods with retaining pins. This prevents elements from coming loose, falling down and injuring people.
Page 179 Boom extension 4.4 Description of rigging work Possible reeving The hoist rope may be reeved a maximum of 1 fall. methods 1-sheave hook block Maximum lifting capacity of the hook block 32 t (70 000 lbs) Maximum lifting capacity with the GMK 5220: A For reeving 1-fall 9.5 t (16 000 lbs)
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Page 181: Working With The Boom Extension
Boom extension 4.5 Working with the boom extension Working with the boom extension When operating the lattice extension or the boom extension, the speed for à Operating instructions the different power units is limited to 70%, GMK 5220 – Crane operation – Adusting power unit speeds . Risk of overturning when working with the boom extension No hook block may be reeved on the main boom during operation with the boom extension.
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Page 183: Driving With Rigged Truck Crane And Rigged Boom Extension
Boom extension 4.6 Driving with rigged truck crane and rigged boom extension Driving with rigged truck crane and rigged boom extension This section describes how you can move the truck crane with installed counterweight and rigged boom extension (e.g if, because of lack of space, the boom extension cannot be directly installed at the site).
Page 184: Driving Route
Boom extension 4.6 Driving with rigged truck crane and rigged boom extension 4.6.1 Driving route The route must be along a flat, even surface. The level adjustment system cannot compensate for uneven surfaces. If the surface pressure of the tyres exceeds the permissible load on the ground, the surface area of the tyres must be increased using packing made of a stable material (e.g.
Page 185: Boom Positions And Axle Loads
Boom extension 4.6 Driving with rigged truck crane and rigged boom extension 4.6.2 Boom positions and axle loads The truck crane may only be moved if certain prerequisites are met. The main boom and the lattice extension must be moved to specified positions, depending on the counterweight installed.
Page 186 Boom extension 4.6 Driving with rigged truck crane and rigged boom extension 29 m (95 ft) boom All the axle loads in the following table apply for reeved hook tackle (weight extension 300 kg (660 lbs)). The maximum axle load specified in the table is reached at a main boom angle of either x°...
Page 187 Boom extension 4.6 Driving with rigged truck crane and rigged boom extension 37 m (121 ft) boom All the axle loads in the following table apply for reeved hook tackle (weight extension 300 kg (660 lbs)). The maximum axle load specified in the table is reached at a main boom angle of either x°...
Page 188: Driving The Rigged Crane
Boom extension 4.7 Maintenance work 4.6.3 Driving the rigged crane When driving with a rigged boom extension, proceed in the same way as à for driving with a rigged lattice extension; p. 3 - 116. Maintenance work 4.7.1 Maintenance work M1, monthly For lubricating the pins, use the same grease as stated in the Maintenance à...
Page 189 Auxiliary single-sheave boom top Identification ............5 - Installing/removing auxiliary single-sheave boom top .
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Page 191: Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top 5.1 Identification Auxiliary single-sheave boom top Identification The auxiliary single-sheave boom top is designed for the truck crane it was delivered with. It has the same serial number as the truck crane. Risk of accidents during operation with non-modified auxiliary single- sheave boom top Operate the truck crane only with the auxiliary single-sheave boom top that has the identical serial number.
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Page 193: Installing/Removing Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top 5.2 Installing/removing auxiliary single-sheave boom top Installing/removing auxiliary single-sheave boom top Risk of accidents if the auxiliary single-sheave boom top should fall off Attach the auxiliary single-sheave boom top only at the designated slinging point. à Auxiliary single- Use only lifting gear with sufficient lifting capacity;...
Page 194: Dismantling The Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top 5.2 Installing/removing auxiliary single-sheave boom top 5.2.2 Dismantling the auxiliary single-sheave boom top • Attach the auxiliary single-sheave boom top at the slinging point (1). à • Lifting Make sure that the electrical connections have been separated; limit switch and anemometer , p.
Page 195: Rigging The Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top 5.3 Rigging the auxiliary single-sheave boom top Rigging the auxiliary single-sheave boom top 5.3.1 Rigging in transport position In the transport position, the auxiliary single-sheave boom top is folded to the left on the main boom. •...
Page 196: Rigging In Working Position
Auxiliary single-sheave boom top 5.3 Rigging the auxiliary single-sheave boom top 5.3.2 Rigging in working position In the working position, the auxiliary single-sheave boom top is locked in front of the main boom. • Pull the lever (4) on the auxiliary single- sheave boom top (1) downwards until the hook (3) is completely released from the latch (2) on the main boom.
Page 197: Attaching And Removing The Hoist Rope
Auxiliary single-sheave boom top 5.3 Rigging the auxiliary single-sheave boom top 5.3.3 Attaching and removing the hoist rope • Remove the cable holding rods (1) from the head of the main boom and from the auxiliary single-sheave boom top. • When reeving, guide the hoist rope over the left head sheave of the main boom.
Page 198: Setting The Sli
Auxiliary single-sheave boom top 5.3 Rigging the auxiliary single-sheave boom top 5.3.4 Setting the SLI • On the SLI, enter the actual rigging mode for operation with the main boom. Use either the corresponding SLI code in accordance with the Lifting capacity table or via individual components.
Page 199: Lifting Limit Switch And Anemometer
Auxiliary single-sheave boom top 5.3 Rigging the auxiliary single-sheave boom top 5.3.5 Lifting limit switch and anemometer Lifting limit switch For operation For each reeved hoist rope, a lifting limit switch must be installed. Information on this can be found in the Operating instructions GMK 5220, Part 2 Crane operation –...
Page 200 Auxiliary single-sheave boom top 5.3 Rigging the auxiliary single-sheave boom top For removal On the left side • Remove the bridging plug (4) from the socket (1) and plug it into the dummy socket (5). • Wind the connecting cable of the plug (4) onto the holder (6).
Page 201: Operation With The Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top 5.4 Operation with the auxiliary single-sheave boom top Operation with the auxiliary single-sheave boom top Operation with the auxiliary single-sheave boom top is carried out in the same way as operation with the main boom. – The hoisting, lowering, slewing, derricking and telescoping movements are carried out in the same way as when operating with the main boom.
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Page 203: Turning Loads With The Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top 5.5 Turning loads with the auxiliary single-sheave boom top Turning loads with the auxiliary single-sheave boom Two-hook operation is required for turning loads. 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. Risk of accidents due to overloading Lifting a load with two hooks is permitted only if the following instructions and illustrations are observed.
Page 204: Setting The Sli
Auxiliary single-sheave boom top 5.5 Turning loads with the auxiliary single-sheave boom top 5.5.2 Setting the SLI You must enter the following settings on the SLI for two-hook operation: – Enter the current reeving for the main and auxiliary hoist. The values are stored and called up directly when switching hoists.
Page 205 Auxiliary single-sheave boom top 5.5 Turning loads with the auxiliary single-sheave boom top Setting the SLI to The SLI always takes into account the reeving entered for the hoist which is displayed at the Hoists indicator lamps. For turning loads, the SLI must take the auxiliary hoist the auxiliary hoist and its reeving into account and both hoists must be switched on.
Page 206: Turning A Load
Auxiliary single-sheave boom top 5.5 Turning loads with the auxiliary single-sheave boom top 5.5.3 Turning a load Carry out the load turning only as it is described in this section. Risk of accidents due to overloading Keep the acceleration forces as low as possible during two-hook operation. For this reason, move the load at the lowest possible speed.
Page 207 Auxiliary single-sheave boom top 5.5 Turning loads with the auxiliary single-sheave boom top • Now lift the load with the hook block on the main boom until both slinging points are at the same height. • Slacken the hoist rope on the auxiliary single-sheave boom top until the load is only hanging from the hook block on the main boom.
Page 208: Driving With Rigged Truck Crane And Rigged Auxiliary Single-Sheave Boom Top
Auxiliary single-sheave boom top 5.6 Driving with rigged truck crane and rigged auxiliary single-sheave boom top Driving with rigged truck crane and rigged auxiliary single-sheave boom top The procedure, tables with boom positions, and axle loads valid for driving with rigged truck crane also apply to driving with rigged auxiliary single- à...
Page 209 Heavy load lattice extension Identification ............6 - Attaching and securing the heavy load lattice extension .
Page 210 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 211: Heavy Load Lattice Extension
Heavy load lattice extension 6.1 Identification Heavy load lattice extension Identification The heavy load lattice extension is matched to the truck crane with which it is delivered. The heavy load lattice extension belonging to the truck crane has the same serial number as the truck crane. Risk of accidents during operation with non-modified heavy load lattice extension Operate the truck crane only with the heavy load lattice extension with the...
Page 212 Heavy load lattice extension 6.1 Identification Blank page 6 - 2 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 213: Attaching And Securing The Heavy Load Lattice Extension
Heavy load lattice extension 6.2 Attaching and securing the heavy load lattice extension Attaching and securing the heavy load lattice extension 6.2.1 Slinging point Risk of accidents due to the heavy load lattice extension falling down Attach the heavy load lattice extension only as described in this section to ensure that it has the right centre of gravity.
Page 214: Securing The Heavy Load Lattice Extension With Guide Rope
Heavy load lattice extension 6.2 Attaching and securing the heavy load lattice extension 6.2.2 Securing the heavy load lattice extension with guide rope Risk of accidents due to the heavy load lattice extension swinging of its own accord Always secure the heavy load lattice extension with a guide rope on the main boom before removing any connections.
Page 215: Installing/Removing The Heavy Load Lattice Extension
Heavy load lattice extension 6.3 Installing/removing the heavy load lattice extension Installing/removing the heavy load lattice extension Risk of accidents due to the heavy load lattice extension falling down Only use appropriate lifting gear having sufficient lifting capacity; à Transport dimensions and weights , p. 2 - 1. 6.3.1 Installing the heavy load lattice extension If the heavy load lattice extension is installed, the swing-away lattice...
Page 216 Heavy load lattice extension 6.3 Installing/removing the heavy load lattice extension • Hoist the heavy load lattice extension on to the left side of the main boom such that the bearing points (2) line up. • Take the pins out of the holders (3) and insert the pins into the bearing points (2).
Page 217: Removing The Heavy Load Lattice Extension
Heavy load lattice extension 6.3 Installing/removing the heavy load lattice extension 6.3.2 Removing the heavy load lattice extension Prerequisites: – The truck crane is on outriggers or the main boom has been placed on the boomsupport. – The required counterweight has been rigged. –...
Page 218 Heavy load lattice extension 6.3 Installing/removing the heavy load lattice extension In working position: The heavy load lattice extension is folded in front of the main boom and is fastened with the pins (1) and (2). • Take the four pins out of the bearing points (2) and insert them into the holders (3) and (5).
Page 219: Rigging The Heavy Load Lattice Extension
Heavy load lattice extension 6.4 Rigging the heavy load lattice extension Rigging the heavy load lattice extension 6.4.1 Rigging in transport position Prerequisites: – The truck crane is on outriggers or the main boom has been placed on the boomsupport. –...
Page 220 Heavy load lattice extension 6.4 Rigging the heavy load lattice extension • Swivel the heavy load lattice extension into the main boom until the bearing points (1) are aligned. • Withdraw the pin from the holder (2) and insert it into the bearing point (1). Secure the pin.
Page 221: Rigging In Working Position
Heavy load lattice extension 6.4 Rigging the heavy load lattice extension 6.4.2 Rigging in working position Prerequisites: – The truck crane is on outriggers or the main boom has been placed on the boomsupport. – Heavy load lattice extension in transport position. –...
Page 222 Heavy load lattice extension 6.4 Rigging the heavy load lattice extension • Swivel the heavy load lattice extension onto the main boom until the bearing point (1) is aligned with the bore hole. • Take the pins out of the bearing points (1) and insert them into the holders (4).
Page 223: Setting The Angle Position Of The Heavy Load Lattice Extension
Heavy load lattice extension 6.4 Rigging the heavy load lattice extension 6.4.3 Setting the angle position of the heavy load lattice extension Depending on requirements, the heavy load 0° angle, lattice extension can be operated at two (transport position) different angles. 30°...
Page 224 Heavy load lattice extension 6.4 Rigging the heavy load lattice extension à • Setting the angle Hook in the chain hoist, Installing/removing the chain hoist , p. 6 - 13. position • Lift the heavy load lattice extension with the 0°...
Page 225: Attaching And Removing The Hoist Rope
Heavy load lattice extension 6.4 Rigging the heavy load lattice extension 6.4.4 Attaching and removing the hoist rope Risk of accidents due to falling parts Always secure the rope holding rollers and rods with retaining pins. This prevents elements from coming loose, falling down and injuring people.
Page 226 Heavy load lattice extension 6.4 Rigging the heavy load lattice extension Possible reeving The hoist rope can be reeved once or twice. methods on the heavy load lattice extension 1-sheave hook block Max. lifting capacity of the hook block 32 t (70 500 lbs) Max.
Page 227: Lifting Limit Switch And Anemometer
Heavy load lattice extension 6.4 Rigging the heavy load lattice extension 6.4.5 Lifting limit switch and anemometer Lifting limit switch For operation For each reeved hoist rope, a lifting limit switch must be installed. Information on this can be found in the Operating instructions GMK 5220, Part 2 Crane operation –...
Page 228 Heavy load lattice extension 6.4 Rigging the heavy load lattice extension For removal On the left side • Remove the plug (3) from the socket (2) and plug it into the dummy socket (4). • Insert the bridging plug (1) into the socket (2).
Page 229: Transportation On A Separate Vehicle
Heavy load lattice extension 6.4 Rigging the heavy load lattice extension 6.4.6 Transportation on a separate vehicle Information on whether the heavy load lattice extension must be removed for driving with a maximum axle load of 12 t can be found in the Operating instructions GMK 5220, Part 1 Crane operation –...
Page 230 Heavy load lattice extension 6.4 Rigging the heavy load lattice extension Blank page 6 - 20 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 231: 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 During operation with the lattice extension, the speed for all power units is limited to 70%. Risk of accidents due to falling chain hoist Always detach the chain hoist before operation with the heavy load lattice extension.
Page 232: Setting The Sli
Heavy load lattice extension 6.5 Operation with the heavy load lattice extension 6.5.1 Setting the SLI If a hook block is reeved on the main boom during operation with the heavy load lattice extension, the loads given in the Lifting capacity tables decrease and the SLI switches off earlier.
Page 233 Heavy load lattice extension 6.5 Operation with the heavy load lattice extension the load according to the Lifting capacity table and the Maximum load display (1) shows the corresponding value. Only the value for the empty hook curve is released and shown when the telescopic sections are unlocked.
Page 234: Raising And Setting Down The Main Boom
Heavy load lattice extension 6.5 Operation with the heavy load lattice extension 6.5.2 Raising and setting down the main boom The following prerequisites must be fulfilled when raising and setting down the main boom with rigged heavy load lattice extension: –...
Page 235: Telescoping With Rigged Heavy Load Lattice Extension
Heavy load lattice extension 6.5 Operation with the heavy load lattice extension 6.5.3 Telescoping with rigged heavy load lattice extension Risk of overloading the main boom If you are telescoping the main boom with the rigged heavy load lattice 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 236: Information About The Sli Shutdown
Heavy load lattice extension 6.5 Operation with the heavy load lattice extension 6.5.4 Information about the SLI shutdown The operation with the heavy load lattice extension is monitored by the SLI. SLI shutdowns can occur during lattice extension operation for the same à...
Page 237: Information About The Main Boom Operation When The Heavy Load Lattice Extension Is Folded/Rigged
Heavy load lattice extension 6.5 Operation with the heavy load lattice extension 6.5.6 Information about the main boom operation when the heavy load lattice extension is folded/rigged This section applies for installed heavy load lattice extension regardless of whether it is in the working position or rigging position. Risk of overturning with impermissible rigging mode Main boom operation with an installed heavy load lattice extension is only permissible in rigging modes that are also permissible for the rigged heavy...
Page 238 Heavy load lattice extension 6.5 Operation with the heavy load lattice extension If this is the case, the SLI is not defective. Do not override the SLI. Even if the displayed value is higher than the calculated value. Risk of accidents with overridden SLI! Do not under any circumstances override the SLI.
Page 239: 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 Two-hook operation is required for turning loads. 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. Risk of accidents due to overloading Lifting a load with two hooks is permitted only if the following instructions and illustrations are observed.
Page 240: Setting The Sli
Heavy load lattice extension 6.6 Turning loads with the heavy load lattice extension 6.6.2 Setting the SLI You must enter the following settings on the SLI for two-hook operation: – Enter the current reeving for the main and auxiliary hoist. The values are stored and called up directly when switching hoists.
Page 241 Heavy load lattice extension 6.6 Turning loads with the heavy load lattice extension Setting the SLI to The SLI always takes into account the reeving entered for the hoist which is displayed at the Hoists indicator lamps. For turning loads, the SLI must take the auxiliary hoist the auxiliary hoist and its reeving into account and both hoists must be switched on.
Page 242: Turning A Load
Heavy load lattice extension 6.6 Turning loads with the heavy load lattice extension 6.6.3 Turning a load Carry out the load turning only as it is described in this section. Risk of accidents due to overloading Keep the acceleration forces as low as possible during two-hook operation. For this reason, move the load at the lowest possible speed.
Page 243 Heavy load lattice extension 6.6 Turning loads with the heavy load lattice extension • Now lift the load with the hook block on the main boom until both slinging points are at the same height. • Slacken the hoist rope on the heavy load lattice extension until the load is only hanging from the hook block on the main boom.
Page 244 Heavy load lattice extension 6.6 Turning loads with the heavy load lattice extension Blank page 6 - 34 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 245: Driving With Rigged Truck Crane And Rigged Heavy Load Lattice Extension
Heavy load lattice extension 6.7 Driving with rigged truck crane and rigged heavy load lattice extension Driving with rigged truck crane and rigged heavy load lattice extension The procedure, tables with boom positions, and axle loads valid for driving with rigged truck crane also apply to driving with rigged heavy load lattice à...
Page 246 Heavy load lattice extension 6.7 Driving with rigged truck crane and rigged heavy load lattice extension Blank page 6 - 36 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 247 Index Lattice extension operating instructions 3 112 319 en GMK 5220...
Page 248 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 249 Index Index The index has the following structure: The names of parts or modules you are searching for are listed in alphabetical order on the left. The following are indented under these terms: – Operations (e.g. Positioning/removing the hoist rope) or –...
Page 250 Index Blank page 7 - 2 3 112 319 en Lattice extension operating instructions GMK 5220...
Page 251 Index Auxiliary single-sheave boom top driving with rigged auxiliary single-sheave boom top ....5 - 18 identification ............5 - 1 installing .
Page 252 Index installing ............6 - 5 operation information about the SLI shutdown .
Page 253 Index derricking the lattice extension ........3 - 91 driving with rigged lattice extension .
Page 254 Index intended use ............1 - 3 organizational measures .

Manitowoc Grove GMK 5220 Instruction Manual

1 1 Important Information

3 3 12/21 M (39/69 Ft) Swing-Away Lattice Extension

3.9.2 Boom Positions and Axle Loads

4 4 Boom Extension

5 5 Auxiliary Single-Sheave Boom Top

6 6 Heavy Load Lattice Extension

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