Grove GMK 5100 User manual

Operating instructions for lattice extension
2 084 770 en
08.05.2003
Serial number:
51009349

©Copyright reserved by Deutsche GROVE GmbH
The passing on or duplication of this document as well as the utilization and disclosure of its contents are prohibited
unless expressly permitted. Infringement will incur liability to compensation. All rights pertaining to registration of patent
or utility model are reserved.
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 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.
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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
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Table of content
1 Important information . . . . . . . . . . . . . . . . . . . 1 - 1
1.1 About these operating instructions . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
1.2.1 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
1.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
1.4 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
1.5 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
1.6 Safety instructions for truck crane work . . . . . . . . . . . . . . . . . . . . . 1 - 8
1.7 The units of measurement in US units . . . . . . . . . . . . . . . . . . . . . . 1 - 10
2 Transport dimensions and weights . . . . . . . . . . . . 2 - 1
2.1 In metric units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
2.1.1 Two-stage swing-away lattice extension and boom extension . . . . . . . 2 - 1
2.1.2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
2.2 In US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
2.2.1 Two-stage swing-away lattice extension and boom extension . . . . . . . 2 - 2
2.2.2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
3 Two-stage swing-away lattice extension
(additional equipment) . . . . . . . . . . . . . . . . . . . 3 - 1
3.1 Identification of the two-stage swing-away lattice extension . . . . . . . . . 3 - 1
3.2 Assembly of lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
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3.3 Centre of gravity positions for slinging . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Check lists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.1 Overview of the required rigging work . . . . . . . . . . . . . . . . . . . . 3 - 5
3.4.2 CHECKLIST: Installing two-stage swing-away lattice extension . . . . . . . 3 - 6
3.4.3 CHECKLIST: Removing (two-stage) swing-away lattice extension . . . . . . 3 - 7
3.4.4 CHECKLIST: Rigging the 11 m swing-away lattice extension . . . . . . . . 3 - 9
3.4.5 CHECKLIST: Unrigging the 11 m swing-away lattice extension . . . . . . . 3 - 13
3.4.6 CHECKLIST: Rigging the 18 m two-stage swing-away lattice extension . . . 3 - 17
3.4.7 CHECKLIST: Unrigging the 18 m two-stage swing-away lattice extension . 3 - 21
3.5 Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27
3.5.1 Preparing the truck crane for rigging . . . . . . . . . . . . . . . . . . . . . 3 - 27
3.5.2 Checking the transport condition . . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
3.5.3 Folding the run-up rail out/in . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32
3.5.4 Connections with folded lattice extension . . . . . . . . . . . . . . . . . . . 3 - 33
3.5.5 Pin connections on the main boom head . . . . . . . . . . . . . . . . . . . 3 - 39
3.5.6 Pin connections on the lattice extension . . . . . . . . . . . . . . . . . . . . 3 - 42
3.5.7 Swivelling lattice extension onto the main boom head . . . . . . . . . . . 3 - 45
3.5.8 Swivelling the lattice extension when rigging . . . . . . . . . . . . . . . . . 3 - 46
3.5.9 Adjusting angle on the lattice extension . . . . . . . . . . . . . . . . . . . . 3 - 48
3.5.10 Folding deflection sheave on 11 m section out/in . . . . . . . . . . . . . . . 3 - 51
3.5.11 Positioning/removing the hoist cable . . . . . . . . . . . . . . . . . . . . . 3 - 52
3.5.12 Electrical connection on the lattice extension . . . . . . . . . . . . . . . . 3 - 55
3.5.13 Lifting limit switch on the lattice extension . . . . . . . . . . . . . . . . . . 3 - 58
3.5.14 Anemometer on the lattice extension . . . . . . . . . . . . . . . . . . . . . 3 - 60
3.5.15 Transportation on a separate vehicle . . . . . . . . . . . . . . . . . . . . . 3 - 61
3.6 Raising and setting down the main boom with rigged lattice extension . . . 3 - 63
3.7 Telescoping with rigged lattice extension . . . . . . . . . . . . . . . . . . . . 3 - 65
3.8 Operation with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . 3 - 67
3.8.1 SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 67
3.8.2 Procedure if the permissible wind speed is exceeded . . . . . . . . . . . . 3 - 68
3.9 Turning loads with the lattice extension . . . . . . . . . . . . . . . . . . . . . 3 - 69
3.9.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 69
3.9.2 Setting SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 70
3.10 Driving with rigged crane and lattice extension installed . . . . . . . . . . . 3 - 73
3.10.1 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 73
3.10.2 Position of the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 74
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3.10.3 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77
3.11 Malfunction when working with lattice extension! . . . . . . . . . . . . . . . 3 - 80
3.12 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 81
3.12.1 Modules requiring protection during cleaning work . . . . . . . . . . . . . 3 - 81
3.12.2 Maintenance work M1, monthly . . . . . . . . . . . . . . . . . . . . . . . . 3 - 82
4 Boom extension (additional equipment) . . . . . . . . . 4 - 1
4.1 Identification and slinging points . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
4.1.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
4.1.2 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
4.2 Assembly of boom extensions . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
4.3 Check lists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
4.3.1 CHECKLIST: Installing the 26 m/34 m boom extension . . . . . . . . . . . . 4 - 5
4.3.2 CHECKLIST: Removing the 26 m/34 m boom extension . . . . . . . . . . . 4 - 8
4.4 Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
4.4.1 Installing/disassembling 8 m sections . . . . . . . . . . . . . . . . . . . . . 4 - 11
4.4.2 Installing/removing two-stage swing-away lattice extension for boom
extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
4.4.3 Electrical connection on the boom extension . . . . . . . . . . . . . . . . . 4 - 13
4.4.4 Folding out/in the deflection sheaves on the 8 m sections . . . . . . . . . . 4 - 15
4.4.5 Positioning/removing the hoist cable . . . . . . . . . . . . . . . . . . . . . 4 - 16
4.5 Driving with a rigged crane if boom extension is rigged . . . . . . . . . . . . 4 - 19
4.5.1 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
4.5.2 Position of the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
4.5.3 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
4.6 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
4.6.1 Maintenance work M1, monthly . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
5 Auxiliary single-sheave boom top (additional equipment) 5 - 1
5.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
5.2 Installing/removing auxiliary single-sheave boom top . . . . . . . . . . . . 5 - 3
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5.2.2 Removing the auxiliary single-sheave boom top . . . . . . . . . . . . . . . 5 - 4
5.3 Rigging the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . 5-5
5.3.1 Rigging in transport position . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
5.3.2 Rigging in working position . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
5.3.3 Attaching and removing hoist cable . . . . . . . . . . . . . . . . . . . . . . 5 - 7
5.3.4 Possible reeving methods on the auxiliary single-sheave boom top . . . . 5 - 7
5.3.5 Lifting limit switch and anemometer . . . . . . . . . . . . . . . . . . . . . 5 - 8
5.4 Turning loads with the auxiliary single-sheave boom top . . . . . . . . . . . 5-9
6 Heavy load lattice extension . . . . . . . . . . . . . . . 6-1
6.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Mount / remove heavy load lattice extension . . . . . . . . . . . . . . . . . . 6-3
6.2.1 Installing the heavy load lattice extension . . . . . . . . . . . . . . . . . . 6 - 3
6.2.2 Removing the heavy load lattice extension . . . . . . . . . . . . . . . . . 6 - 4
6.3 Rigging work check lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.1 CHECK LIST: Changing the heavy load lattice extension . . . . . . . . . . 6 - 5
6.3.2 CHECK LIST: Unrigging heavy load lattice extension . . . . . . . . . . . . 6 - 7
6.4 Rigging / unrigging the heavy load lattice extension . . . . . . . . . . . . . 6-9
6.4.1 Rigging the heavy load lattice extension . . . . . . . . . . . . . . . . . . . 6 - 9
6.4.2 Removing the heavy load lattice extension . . . . . . . . . . . . . . . . . . 6 - 19
6.5 Operation with the heavy load lattice extension . . . . . . . . . . . . . . . . 6 - 21
6.5.1 Telescoping with rigged heavy load lattice extension . . . . . . . . . . . . 6 - 22
6.5.2 Raising and placing the main boom with rigged heavy load lattice
extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22
6.6 Turning loads with the heavy load lattice extension . . . . . . . . . . . . . . 6 - 23
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1Important information
1.1 About these operating instructions
HAll the lattice extensions described in these operating instructions can be
obtained as additional equipment.
Validity of this
operating manual
This operating manual only applies to lattice extensions which were deli-
vered by Deutsche GROVE GmbH.
In addition, for the operation of the truck crane with a lattice extension
described in these operating instructions, all details in the included Opera-
ting Instructions for the GMK 5100 (for which the lattice extension was deli-
vered from the factory) are applicable.
Prerequisites for
assembly and
operation
The lattice extensions described in these operating instructions may only
be operated together with a GROVE GMK 5100 truck crane whose serial
number is identical with the serial number that is marked on the lattice ex-
tensions.
Safety
instructions
The operation of the GMK 5100 with one of the lattice extensions descri-
bed in these operating instructions is subject to
– all the basic safety instructions to be found in the subsequent section
Basic safety instructions and
– all the safety instructions contained in the supplied operating instructi-
ons for the GMK 5100.
Reference to
other operating
instructions
Cross references to other operating or maintenance instructions are sta-
ted as follows:
➠GMK 5100 Operating Instructions, part 2 Superstructure – Rigging work
You will find the number of the chapter bearing the name Rigging work at
the front, on the second page of the stated operating instructions.
s
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Important information
1.1 About these operating instructions
Operating instructions for lattice extension 2 084 770 en 1 - 1
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1.2 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:
GThis symbol indicates hazards related to the described operation that
may cause personal injury. The type of danger (e.g. danger of life, perso-
nal injury or risk of crushing) is as a rule specified in the warning sign.
SHere dangers are referred to which could put objects at risk, e.g. damage
to the truck crane, the load or the environment.
BThis symbol alerts you to situations where you are in danger of receiving
an electric shock.
OThis symbol is to remind you that you are working with substances which
pose a risk to the environment. Take particular care. Further information
about handling substances which are harmful to the environment;
➠Maintenance manual, Chapter Safety and environmental protection.
The vertical line to the left of the text indicates: this text regardless of its
length belongs to the warning symbol.
HThe hand with the pointing finger indicates passages that contain additio-
nal instructions and tips with regard to truck crane operation.
sThis symbol indicates that the topic is continued on the next page. So
turn to the next page!
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Important information
1.2 Basic safety instructions
1 - 2 2 084 770 en Operating instructions for lattice extension
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