6

Boom extension

6.1 Notes on this chapter

HTo assemble a boom extension A, B, C, D or E you need one or two sections5 and different parts of the swing-away lattice. The combinations D and E are intended only for the GMK5150.

This chapter describes the installation and removal of section5 and section4.

The other sections are installed and removed in the same manner as the swing-away lattice. Reference is therefore made to the Swing-away lattice chapter where appropriate.

The figures in this chapter show the rigging procedure for boom extension C and E, in which only section4 is installed and removed. With the other boom extensions, section4 can be installed with a section combination (1) or(2) as long as appropriate slinging points are provided for the combination.

6.2 Operations planning

6.2.1 Assembly

SRisk of overturning in other combinations!

Assemble the boom extension only in the permissible combinations as specified in the lifting capacity table. Other combinations are not monitored by the RCL.

CombinationDesignationZ + Y 1) Sections used

1) Designation in the lifting capacity table: Z = length before setting the angle Y = length after setting the angle

2) Only for GMK5150

6.2.2 Identification

Section5

GRisk of accidents when using an incorrect boom extension! Install only the section5 that belongs to the specific truck crane. Other boom extensions must not be installed.

The truck crane and the corresponding section5 must be labelled with the same serial number (1).

6.2.3 Slinging points

Section5

GRisk of accidents if used improperly!

Sling section5 to the slinging points provided. Use only lifting gear and joining elements of sufficient load bearing capacity.

The slinging points (1) are marked with stickers (5).

The information on the weight and the necessary lifting gear is provided on the sticker (3) for the derricking design and the sticker (4) for the inclinable design.

The grille (2) serves as the slinging point for the guide rope.

6.2.4 Transport dimensions and weights

6.2.5 Transport condition

Section5

• Check that the heavy lattice load extension is secure for transport or secure it now, if necessary.

–All pins (1) are secured in the clamps.

–The electrical cable is closed with the cap(3).

–The plug (5) has been inserted in the dummy socket.

–The deflection sheave (6) is folded in and secured.

–The section5 must be secured to a suitable support (7).

–With the derricking design, all hoses are closed with the caps (2) and wound onto the clamp (4).

6.3 Checklists for rigging work

6.3.1 Overview

The following table shows which checklist is applicable for any required rigging work.

Required rigging workChecklist

–Installing the boom extension CHECKLIST: Installing the boom extension, p.6-10

Boom extension

–Removing the boom extension CHECKLIST: Removing the boom extension, p.6-15

6.3.2 CHECKLIST: Installing the boom extension

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite

–The truck crane is supported on outriggers; à GMK5150 / GMK5150L Operating Instructions

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

–The swing-away lattice is removed.

–An auxiliary crane must be available.

2. If necessary, mount the hose drum; à p.4-3.

3. If necessary, check that the locking device has been released; à p.4-5.

4. If necessary, move the hoses into the position for working with the lattice extension; à p.4-6.

5. Check the transport condition of section5; à p.6-8.

6. Fold out and secure the deflection sheave on section5; à p.6-21.

7. –Attach slings to section5 and attach a guide rope. –Lift section5 into position in front of the main boom. à Identification, p.6-6, à Transport dimensions and weights, p.6-8, à Slinging points, p.6-7.

8. –Establish a connection between section5 and the main boom; à p.6-22.

–Remove the lifting gear and the guide rope.

9. Establish electrical connection between section5 and the main boom; à p.6-23.

10. If necessary, establish a hydraulic connection between section5 and the main boom; à p.6-25.

11. For combination D or E à Identification, p.6-6, à Transport dimensions and weights, p.6-8, à Slinging points, p.6-7

–Check the transport condition of section5; à p.6-8.

–Fold out and secure the deflection sheave on section5; à p.6-21.

–Attach slings to section5 and attach a guide rope.

–Lift section5 into position in front of section5.

–Establish a connection between section5 and section5; à p.6-26. –Remove the lifting gear and the guide rope.

–Establish electrical connection between section5 and section5; à p.6-27.

–If necessary, establish a hydraulic connection between section5 and section5; à p.6-29.

12. Check the transport condition of the swing-away lattice; à p.5-8.

13. Fold out and secure the deflection sheaves. –On section4; à p.6-30. –If necessary, at section2; à p.6-31.

14. Depending on the boom extension, sling the necessary sections of the swing-away lattice and fasten a guide rope. à Assembly, p.6-3. à Slinging points, p.5-4.

15. –Lift section4 into position in front of section5.

–Establish the connection between section4 and section5; à p.6-32.

–Remove the lifting gear and the guide rope.

16. Establish the electrical connection between section4 and section5; à p.6-33.

17. If necessary, establish a hydraulic connection between section4 and section5; à p.6-35.

18. Place the hoist rope on section5; à p.6-36

HFurther installation is performed in the same manner as installation of the swing-away lattice. This is described in the checklist CHECKLIST: Installing the swing-away lattice – into the operating position

19. Perform the required steps.

–For boom extension A

Perform all steps for installing the swing-away lattice 1.8 + 9.4m starting from point 13.; à p.5-22.

–For boom extensions B and D

Perform all steps for installing the swing-away lattice 1.8 + 16.0m starting from point 15.; à p.5-23.

–For boom extensions C and E

Perform all steps for installing the swing-away lattice 1.8 + 24m starting from point 14.; à p.5-22

6.3.3 CHECKLIST: Removing the boom extension

H This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite

–The truck crane is supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

–An auxiliary crane must be available.

H Removal is started in the same manner as removal of the swing-away lattice. This is described in the checklist CHECKLIST: Removing the swing-away lattice – from the operating position.

2. Carry out all the necessary steps in the checklist CHECKLIST: Removing the swing-away lattice – from the operating position (à p.5-30) until only section4 is mounted on section5 or until only a section combination is mounted for which slinging points are provided. Possible section combinations and slinging points; à p.5-4.

–For boom extension A

Perform all steps for removing the swing-away lattice 1.8 + 9.4m up to and including step 9.

–For boom extensions B and D

Perform all steps for removing the swing-away lattice 1.8 + 16.0m up to and including step 10.

–For boom extensions C and E

Perform all steps for removing the swing-away lattice 1.8 + 24m up to and including step 11.

3. Unreeve the hoist rope and remove it from section5; à p.6-36.

If necessary, roll the hoist rope onto drum up to the main boom head.

4. Depending on the boom extension, sling the necessary sections of the swing-away lattice and fasten a guide rope.

–Sections required; à p.6-3.

–Possible section combinations and slinging points; à p.5-4.

5. Disconnect the electrical connection between section4 and section5; à p.6-34.

6. If necessary, disconnect the hydraulic connection between section4 and section5; à p.6-35.

7. Disconnect the connection between section4 and section5; à p.6-32.

8. Lift the swing-away lattice off section5 and set it down.

9. Fold in and secure the deflection sheaves. –On section4; à p.6-30. –If necessary, at section2; à p.6-31.

10. Check the transport condition of the swing-away lattice; à p.5-8.

11. For combination D or E

–Disconnect the electrical connection between section5 and section5; à p.6-28.

–If necessary, disconnect the hydraulic connection between section5 and section5; à p.6-29.

–Attach slings to section5 and attach a guide rope: à Identification, p.6-6, à Transport dimensions and weights, p.6-8, à Slinging points, p.6-7.

–Disconnect the connection between section5 and section5; à p.6-26.

–Remove section5 from section5 and put it aside.

–Fold in and secure the deflection sheave at section5; à p.6-21.

–Check the transport condition of section5; à p.6-8.

12. Disconnect the electrical connection between section5 and the main boom; à p.6-24.

13. If necessary, disconnect the hydraulic connection between section5 and the main boom; à p.6-25.

14. Attach slings to section5 and attach a guide rope: à Identification, p.6-6, à Transport dimensions and weights, p.6-8, à Slinging points, p.6-7.

15. Disconnect the connection between section5 and the main boom; à p.6-22.

16. Remove section5 from the main boom and put it aside.

17. Fold in and secure the deflection sheave at section5; à p.6-21.

18. Check the transport condition of section5; à p.6-8.

19. Reeve the hoist rope on to the main boom head, or roll it onto the drum; à GMK5150 / GMK5150L Operating Instructions

20. If necessary, move the hoses into the position for main boom operation; à p.4-6.

21. If necessary, remove the hose drum; à p.4-3

6.4 Description of the rigging work

6.4.1 Section5 – Folding out/folding in the deflection sheave

GRisk of crushing!

Always hold the deflection sheave firmly by the handle when removing the pin.

Your fingers may be crushed if you hold the sheave by the side panel.

Folding out

• (A) – Hold the deflection sheave (2) firmly by the handle (1) and pull out the pin (3).

• (B) – Fold the deflection sheave (2) upwards until the connecting points align.

• Insert the pins (3) into the connecting points.

• Secure the pins.

Folding in

• (A) – Hold the deflection sheave (2) firmly by the handle (1) and pull out the pin (3).

• (B) – Fold the deflection sheave (2) downwards until the connecting points align.

• Insert the pins (3) into the connecting points.

• Secure the pins.

6.4.2 Section5/main boom – Establish/separate the connection

GRisk of accidents due to swinging parts! Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–Section5 must be attached to an auxiliary crane. –A guide rope must be attached.

Connecting

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2).

• Secure the pins.

Disconnecting

• Remove the pins (1) from the connecting points (2) and insert them into the clamps(3).

• Secure the pins.

6.4.3 Section5/main boom – Establish/separate the electrical connections

Making the electrical connections

• Unwind the cable (3) from the clamp (4).

• Remove the plug (2) from the dummy socket(5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the clamp (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the clamp (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the clamp (4).

• Close the plug (2) and the socket (1) with the caps.

6.4.4 Section5/main boom – Establish/separating the hydraulic connection

Connecting

• Remove the hoses (2) from the clamps (3).

• Connect the hoses (2) to the connections (1) (match the markings).

Disconnecting

• Remove the hoses (2) from the connections(1).

• Close the hoses (2) and the connections (1) with the caps.

• Secure the hoses (2) on the clamp (3) on section5.

6.4.5 Section5/section5 – Establish/separate the connection

GRisk of accidents due to swinging parts! Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–Section5 must be attached to an auxiliary crane. –A guide rope must be attached.

Connecting

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2).

• Secure the pins.

Disconnecting

• Remove the pins (1) from the connecting points (2) and insert them into the clamps(3).

• Secure the pins.

6.4.6 Section5/section5 – Establish/separate the electrical connections

Making the electrical connections

• Unwind the cable (3) from the clamp (4).

• Remove the plug (2) from the dummy socket(5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the clamp (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the clamp (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the clamp (4).

• Close the plug (2) and the socket (1) with the caps.

6.4.7 Section5/section5 – Establish/separating the hydraulic connection

Connecting

• Remove the hoses (2) from the clamps (3).

• Connect the hoses (2) to the connections (1) (match the markings).

Disconnecting

• Remove the hoses (2) from the connections(1).

• Close the hoses (2) and the connections (1) with the caps.

• Secure the hoses (2) on the clamp (3) on section5.

6.4.8 Section4 – Folding out/folding in the deflection sheave

GRisk of crushing!

Always hold the deflection sheave firmly by the handle when removing thepin.

Your fingers may be crushed if you hold the sheave by the side panel.

Folding out

• (A) – Hold the deflection sheave (3) firmly by the handle (1) and pull out the pin (2).

• (B) – Fold the deflection sheave (3) upwards until it is aligned with the connecting point.

• Insert the pin (2) into the connecting point.

• Secure the pin.

Folding in

• (A) – Hold the deflection sheave (3) firmly by the handle (1) and pull out the pin (2).

• (B) – Fold the deflection sheave (3) downwards until it is aligned with the connecting point.

• Insert the pin (2) into the connecting point.

• Secure the pin.

6.4.9 Section2 – Folding out/folding in the deflection sheave

GRisk of crushing!

Always hold the deflection sheave by the strut when removing the pin. Your fingers may be crushed if you hold the sheave by the side panel.

Folding out

• (A) – Hold the deflection sheave (2) firmly by the strut (1) and pull out the pin (3).

• (B) – Fold the deflection sheave (2) upwards until it is aligned with the connecting point.

• Insert the pin (3) into the connecting point.

• Secure the pin.

Folding in

• (A) – Hold the deflection sheave (2) firmly by the strut (1) and pull out the pin (3).

• (B) – Fold the deflection sheave (2) downwards until it is aligned with the connecting point.

• Insert the pin (3) into the connecting point.

• Secure the pin.

6.4.10

Section4/section5 – Establishing/separating the connection

GRisk of accidents due to swinging parts! Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–The swing-away lattice is slung on an auxiliary crane. –A guide rope must be attached.

Connecting

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2).

• Secure the pins.

Disconnecting

• Remove the pins (1) from the connecting points (2) and insert them into the clamps(3).

• Secure the pins.

6.4.11 Section4/section5 – Establishing/separating the electrical connections

Making the electrical connections

• Unwind the cable (3) from the clamp (4).

• Remove the plug (2) from the dummy socket(5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the clamp (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the clamp (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the clamp (4).

• Close the plug (2) and the socket (1) with the caps.

6.4.12 Section4/section5 – Establishing/separating the hydraulic connection

Connecting

• Remove the hoses (2) from the clamp (3).

• Connect the hoses (2) to the connections (1) (match the markings).

Disconnecting

• Remove the hoses (2) from the connections(1).

• Close the hoses (2) and the connections (1) with the caps.

• Secure the hoses (2) on the clamp (3) on section4.

6.4.13 Section5 – Fitting/removing the hoist rope

GRisk of accidents due to falling parts! Always secure the sheaves and rods with retaining pins. This prevents sections coming loose, falling out and causing injuries.

HThis section describes the procedure for the boom extension E. Only a one section5 is present for boom extension C.

Fitting

• Remove the sheaves (3) and (4).

• Guide the hoist rope over the deflection sheaves (1) and (2) up to section4.

• Install sheaves (3) and (4).

• Secure the sheaves.

Removing

• Remove the sheaves (3) and (4).

• Remove the hoist rope from the deflection sheaves (1) and (2) and set it down on the ground or reel it in up to the main boom head or up to the rope drum.

• Install sheaves (3) and (4).

• Secure the sheaves.

6.5 Operation with boom extension

6.5 Operation with boom extension

Risk of accidents due to overloading!

Crane operation with the main boom is prohibited when a boom extension is rigged.

Lifting a load with two hooks is prohibited when a boom extension is rigged.

The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will need additionally for a rigged boom extension.

6.5.1 Setting the RCL

Input

• Enter the current rigging mode for operation with a rigged boom extension into the RCL. Either via the corresponding RCL code in accordance with the lifting capacity table or via the individual components.

If you enter the current rigging mode via the individual components then you must also additionally enter the length of the boom extension.

• Enter the current reeving on the boom extension for the hoist whose hoist rope is reeved on the boom extension into the RCL. H

The lifting capacity for the RCL code is enabled once the telescopic sections are locked.

Shutdown Operation with the boom extension is monitored by the RCL.

When operating with the boom extension, RCL shutdowns may occur for the same reasons as when operating with the main boom; à GMK5150 / GMK5150L Operating Instructions.

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table

–During operation with the boom extension

If a hook block (3) is reeved at the main boom, then the displayed current load (1) is influenced by

–The weight of the lifted load (2) and

–The weight of the hook block (3).

6.5.2 Derricking, telescoping the main boom

Slewing range of360°

GRisk of accidents if the RCL is overridden!

Do not override the RCL when lowering the boom into horizontal position. If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The requirements that must be satisfied before raising, lowering and telescoping of the main boom with rigged boom extension are permitted, for a slewing range of 360° are monitored by the RCL. Further information on the permissible angle ranges and lifting capacities is provided in the lifting capacity table; à Rigging tables - lattice extension

The hook block can hit the main boom if the main boom is set to a steep angle and the boom extension is set to 0°.

6.5.3 Procedure if permissible wind speeds are exceeded

GRisk of accidents due to excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

This will prevent the truck crane from overturning due to overload.

• Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed.

• Make sure that you follow the instructions for checking the wind speed; à Lifting capacity table and à GMK5150 / GMK5150L Operating Instructions.

If the maximum permitted wind speed is exceeded:

An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

• Put the truck crane into the rigging mode specified for the current wind speed in the lifting capacity table.

6.5.4 Instructions for turning loads over

Turning loads over with a rigged boom extension is prohibited.

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6.6 Maintenance

HIf the boom extension has been in storage for an extended period of time, perform maintenance work on it before the next time it is used, at the very latest.

1

Maintenance work on the BOOM EXTENSION: Monthly/after approx. 100 operating hours

Boom extension

–Lubricate the pins à p.6-42 M 3

Maintenance work on the BOOM EXTENSION: every three months/after 250 oper. hrs.

Boom extension

–Check the sheaves à p.6-42

6.6.3 Description of maintenance work

Lubricate the pins

• Grease the pins (1).

Check the sheaves

• Check the deflection sheave (2) for damage, wear, freedom of movement and heavy soiling.

• Have damaged, worn, stiff or extremely soiled sheaves replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

7

Integral heavy load lattice extension (ISS)

1.8+2.0m/9.8 + 2.0m

This chapter describes the rigging work on the integral heavy load lattice extension (1).

Information

Section1 and section2 (1) of the swing-away lattice can remain folded onto the main boom during crane operation with the integral heavy load lattice extension.

On-road driving with section1 and section2 (1) of the swing-away lattice without an installed heavy load lattice extension folded onto the main boom is prohibited. The connections are not designed for this.

7.1 Operations planning

7.1.1 Assembly

SRisk of overturning in other combinations! Assemble the heavy load lattice extension only in the combinations listed as permissible in the lifting capacity table. Other combinations are not monitored by the RCL.

Permissible combinations

7.1.2 Identification

GRisk of accidents if ISS are interchanged! Install only the ISS that belongs to the crane. No other integral heavy load lattice extensions may be installed.

Section4

The crane and the corresponding section4 must carry the same serial number (1).

Section5

The crane and the corresponding section5 must carry the same serial number (1).

7.1.3 Slinging points

GRisk of accidents if used improperly! Attach slings to the ISS only at the designated attachment points. Use only lifting gear and joining elements of sufficient load bearing capacity.

Section4

The slinging points (1) are marked with the sticker (2).

The sticker (3) gives data on the weight and the necessary lifting gear.

The rope attachment point (4) serves as the slinging point for the guide rope.

Section5

The slinging points (1) are marked with stickers (2).

The sticker (3) gives data on the weight and the necessary lifting gear.

The grille (4) serves as the slinging point for the guide rope.

7.1.4 Transport dimensions and weights

7.1.5 Transport condition – removed

Section4

• Check that the ISS is secured in the transport condition and secure it now if necessary:

–Section4 must be set down on a suitable support (1), and secured.

–All pins (2) are secured in the holders.

–The hoses (3) must be wound on to the holders.

–The head sheave (5) and the deflection sheave (4) must be folded in and secured.

–The plug (8) is inserted and the socket (6) is closed with the cap.

–The derricking cylinder is in position (A) (7); à p.7-78.

Section5

• Check that the ISS is secured in the transport condition and secure it now if necessary:

–All pins (1) are secured in the holders.

–All hoses (2) and electrical cables (3) must be closed with caps.

–The hoses (4) must be wound on to the holder.

–The plug (5) has been inserted in the dummy socket.

–The deflection sheave (6) is folded in and secured.

–The section5 must be secured to a suitable base plate support (7).

7.1.6 Transport condition – folded

Section4

• Check that the ISS is secured in the transport condition and secure it now if necessary:

–The socket (1) is closed with the protective cap.

–The derricking cylinder is in position (A) (2); à p.7-78.

–The plug (3) is inserted.

–The Middle 2 connection (4) is established; à p.7-46.

–The front connection (5) is in the Locked position; à p.5-71.

–The hoses (6) must be wound on to the holders.

–The head sheave (7) and the deflection sheave (8) must be folded in and secured.

7.2 Checklists for rigging work

7.2.1 Overview

The following table shows which checklist is applicable for any required rigging work.

Required rigging workChecklist

–Installing the ISS–In working position

–Removing the ISS

–From working position

–Rigging the ISS–In working position

CHECKLIST: ISS Installing 1.8 + 2.0m – into the working position, p.7-10

CHECKLIST: ISS Removing 1.8 + 2.0m – from the working position, p.7-13

CHECKLIST: Rigging ISS 1.8 + 2.0m – into the working position, p.7-17

ISS 1.8 + 2.0m

–Rigging the ISS from the swingaway lattice

–in transport position

–in working position

CHECKLIST: Rigging ISS 1.8 + 2.0m – into the transport position, p.7-21

CHECKLIST: Rigging ISS 1.8 + 2.0m from the swing-away lattice – into the working position, p.7-26

–in transport position CHECKLIST: Rigging ISS 1.8 + 2.0m from the swing-away lattice – into the transport position, p.7-30

–Disconnecting ISS/ section2

–Connecting ISS/section2 à Establishing/separating connections between section4 and section2, p.7-50

ISS 9.8 + 2.0m

–Installing the ISS–in working position

–Removing the ISS

–From working position

CHECKLIST: ISS Installing 9.8 + 2.0m, p.7-35

CHECKLIST: ISS Removing 9.8 + 2.0m, p.7-39

7.2.2 CHECKLIST: ISS Installing 1.8 + 2.0m – into the working position

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites

–The truck crane is on outriggers and the superstructure is turned to the side or to the rear; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions

–The main boom is fully retracted and locked. The telescoping cylinder must be locked in telescopic section V; à p.5-65.

The main boom is lowered to the horizontal position; à GMK5150 / GMK5150L Operating Instructions

–An auxiliary crane must be available.

2. If necessary, mount the hose drum; à p.4-3

3. If necessary, check that the locking device has been released; à p.4-5.

4. If necessary, move the hoses into the position for working with the lattice extension; à p.4-6.

5. Check that section4 is secured in the transport condition; à p.7-5.

6. Fold out the deflection sheave on section4; à p.7-56.

7. Fasten slings to section4 and attach a guide rope: – à Identification, p.7-3 à Transport dimensions and weights, p.7-5 – à Slinging points, p.7-4.

8. Lift section4 into position in front of the main boom.

9. Make the connections on the right and left of the main boom head; à

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

10. Establish the electrical and hydraulic connections: –Electrical connection; à p.7-53, –Hydraulic connection; à p.7-55.

11. Fold out the head sheave; à p.7-57.

12. Position the hoist rope; à p.7-58.

13. Perform all further rigging work; à p.7-43.

14. If necessary, derrick the ISS; à p.7-79.

7.2.3 CHECKLIST: ISS Removing 1.8 + 2.0m – from the working position

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites

–The truck crane is on outriggers and the superstructure is turned to the side or to the rear; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions

–The main boom is fully retracted and locked.

The telescoping cylinder must be locked in telescopic section V; à p.5-65.

The main boom is lowered to the horizontal position; à GMK5150 / GMK5150L Operating Instructions

–An auxiliary crane must be available.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

4. If necessary, remove the camera; à p.7-66.

5. Remove the lifting limit switch weight and lifting limit switch; à p.7-63.

6. Unreeve the hoist rope and remove it from section4; à p.7-58.

7. Fold the head sheave in, à p.7-57.

8. Fasten slings to section4 and attach a guide rope; à p.7-4.

9. Disconnect the electric and hydraulic connections: –Electrical connection; à p.7-53, –Hydraulic connection; à p.7-55.

10. Separate the connections on the right and left of the main boom head; à p.7-48.

11. Remove section4 from the main boom and put it aside.

12. If necessary, move the hoses into the position for working with the main boom; à p.4-6.

13. If necessary, remove the hose drum; à p.4-3

14. Fold in the deflection sheave and secure it; à p.7-56.

15. Reeve the hoist rope on to the main boom head, or roll it onto the drum; à GMK5150 / GMK5150L Operating Instructions

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

16. Secure section4 in the transport condition; à p.7-5.

7.2.4 CHECKLIST: Rigging ISS 1.8 + 2.0m – into the working position

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites

–The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom is fully retracted and locked. The telescoping cylinder must be locked in telescopic section V; à p.5-65.

The main boom is lowered to the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

2. If necessary, mount the hose drum; à p.4-3

3. If necessary, check that the locking device has been released; à p.4-5.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

4. If necessary, move the hoses into the position for working with the lattice extension; à p.4-6.

5. Connect the hand-held control; à p.3-13.

6. Fasten the guide rope to section4; à p.7-4.

7. Establish the hydraulic and electrical connections between section4 and the main boom: –Hydraulic connection; à p.7-55, –Electrical connection; à p.7-53.

8. Disconnect the Middle 2 connection; à p.7-46.

9. Swing section4 outwards until the slewing connection lines up.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

16. Position the hoist rope; à p.7-58.

17. Reeve the hook block; à GMK5150 / GMK5150L Operating Instructions.

18. Disconnect the hand-held control; à GMK5150 / GMK5150L Operating Instructions.

19. Remove the guide rope.

20. Perform all further rigging work; à p.7-43.

7.2.5 CHECKLIST: Rigging ISS 1.8 + 2.0m – into the transport position

HThis checklist is not equivalent to the complete operating instructions. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisites

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The counterweight must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom is fully retracted and locked. The telescoping cylinder must be locked in telescopic section V; à p.5-65.

The main boom is lowered to the horizontal position; à GMK5150 / GMK5150L Operating Instructions

2. Connect the hand-held control; à Hand-held control connection, p.3-13.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

5. Remove the lifting limit switch weight and lifting limit switch; à p.7-63.

6. If necessary, remove the camera; à p.7-66.

7. Unreeve the hook block and remove the hoist rope; à

11. Make the slewing connection; à p.5-73.

12. Separate the connections on the right-hand side and left-hand side between section4 and the main boom; à p.5-75.

13. Set the Front connection to the Rigging position; à p.5-71.

14. Swing section4 onto the main boom until section4 in latches into the Front connection. Set the Locked position; à p.5-71.

15. Disconnect the slewing connection; à p.5-73.

16. Swing the ISS onto the main boom until the connecting point on the ISS is aligned with the Middle 2 connection; à p.7-46. If necessary, follow with the derricking cylinder.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

17. Establish the Middle 2 connection; à p.7-46.

18. Disconnect the electrical and hydraulic connections between section4 and the main boom: –Electrical connection; à p.7-73, –Hydraulic connection; à p.7-75.

19. If necessary, move the hoses into the position for working with the main boom; à p.4-6.

20. If necessary, remove the hose drum; à p.4-3

21. Disconnect the hand-held control; à GMK5150 / GMK5150L Operating Instructions.

22. Remove the guide rope.

23. Check the transport condition of the ISS; à p.7-7.

7.2.6 CHECKLIST: Rigging ISS 1.8 + 2.0m from the swing-away lattice – into the working position

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The counterweight must be rigged; à GMK5150 / GMK5150L Operating Instructions

–The swing-away lattice must be folded onto the side of the main boom; à Transport condition – folded , p.5-12.

–The main boom is fully retracted and locked. The telescoping cylinder must be locked in telescopic section V; à Notes on the position of the telescoping cylinder, p.5-65. The main boom is lowered to the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

2. If necessary, mount the hose drum; à p.4-3

3. Check that the locking device has been released; à p.4-5.

4. Position hydraulic hoses for working with the lattice extension; à p.4-6.

5. Connect the hand-held control; à p.3-13.

6. Fasten the guide rope to section4; à p.7-4.

7. Establish the hydraulic and electrical connections between section4 and the main boom: –Hydraulic connection; à p.7-55, –Electrical connection; à p.7-53.

8. Disconnect the electrical connection between section4 and section2; à p.7-61.

9. Disconnect the connection between section4 and section2; à p.7-50.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

7.2.7 CHECKLIST: Rigging ISS 1.8 + 2.0m from the swing-away lattice – into the transport position

HThis checklist is not equivalent to the complete operating instructions. There are accompanying instructions, which are indicated by cross-references.

Observe the warnings and safety instructions there!

1. Prerequisites

–The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions

–The main boom is fully retracted and locked. The telescoping cylinder must be locked in telescopic section V; à p.5-65.

2. Fasten the guide rope to section4; à p.7-4.

3. Connect the hand-held control; à p.3-13.

4. Remove the anemometer and if necessary the air traffic control light; à p.7-64.

5. Remove the lifting limit switch weight and lifting limit switch; à p.7-63.

6. If necessary, remove the camera; à heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

11. Lower section4 by approx. 15° using the derricking cylinder.

12. Separate the connections on the right-hand side and left-hand side between section4 and the main boom; à p.5-75.

13. Set the Front connection to the Rigging position; à p.5-71.

14. Swing section4 onto the main boom until section4 in latches into the Front connection. Set the Locked position; à p.5-71.

15. Disconnect the slewing connection; à p.5-73.

16. Swing section4 on to the main boom until the connecting points of section4 and section2 are underneath each other.

17. Lower the derricking cylinder until the connecting points section4 and section2 align; à p.5-113.

18. Establish the connection between section4 and section2; à p.7-50.

19. Establish the electrical connection between section4 and section2; à p.7-61.

20. Disconnect the electrical and hydraulic connections between section4 and the main boom; –Hydraulic connection; à p.7-55, –Electrical connection; à p.7-53.

21. Bring the hydraulic hoses into the position for working with the main boom; à p.4-6.

22. If necessary, remove the hose drum; à p.4-3.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

23. Reeve the hoist rope on to the main boom head, or roll it onto the drum; à GMK5150 / GMK5150L Operating Instructions

24. Check that the swing-away lattice is secured in the transport condition; à p.5-12.

7.2.8 CHECKLIST: ISS Installing 9.8 + 2.0m

H This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom is fully retracted and locked. The telescoping cylinder must be locked in telescopic section V; à p.5-65.

The main boom is lowered to the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

–An auxiliary crane must be available.

2. If necessary, mount the hose drum; à p.4-3

3. If necessary, check that the locking device has been released; à p.4-5.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

4. If necessary, move the hoses into the position for working with the lattice extension; à p.4-6.

5. Check the transport condition for section5, establish it if necessary; à p.7-5.

6. Check the transport condition for section4, establish it if necessary; à p.7-5.

7. Fold out the deflection sheave on section5; à p.7-67.

8. Fasten slings to section5 and attach a guide rope: – à Identification, p.7-3, – à Transport dimensions and weights, p.7-5, – à Slinging points, p.7-4.

9. Lift section5 in front of the main boom and establish the left-hand and right-hand connections; à p.7-68.

10. Establish the electrical and hydraulic connections between section5 and the main boom:

–Electrical connection; à p.7-69, –Hydraulic connection; à p.7-71.

11. Fold out the deflection sheave on section4; à p.7-56.

12. Fasten slings to section4 and attach a guide rope: – à Identification, p.7-3, – à Transport dimensions and weights, p.7-5, – à Slinging points, p.7-4.

13. Lift section4 up in front of section5.

14. Establish the connection between section4 and section5; à p.7-72.

15. Establish the electrical and hydraulic connections between section4 and section5:

–Electrical connection; à p.7-73, –Hydraulic connection; à p.7-75.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

16. Fold out the head sheave; à p.7-57.

17. Position the hoist rope; à p.7-76.

18. Perform all further rigging work; à p.7-43.

If necessary, derrick the ISS; à p.7-79.

7.2.9 CHECKLIST: ISS Removing 9.8 + 2.0m

H This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom is fully retracted and locked. The telescoping cylinder must be locked in telescopic section V; à p.5-65.

The main boom is lowered to the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

–An auxiliary crane must be available.

2. Derrick section4 into position (A); à p.7-78.

3. Remove the anemometer and if necessary the air traffic control light; à p.7-64.

4. If necessary, remove the camera; à p.7-66.

5. Remove the lifting limit switch weight and lifting limit switch; à p.7-63.

6. Unreeve the hoist rope, remove it from the ISS and roll it on to the drum up to the main boom head; à p.7-76.

7. Fold in the head sheave; à p.7-57.

8. Fasten slings to section4 and attach a guide rope:

– à Identification, p.7-3

– à Transport dimensions and weights, p.7-5

– à Slinging points, p.7-4

9. Disconnect the electrical and hydraulic connections between section4 and section5:

–Electrical connection; à p.7-73, –Hydraulic connection; à p.7-75.

10. Disconnect the connection between section4 and section5; à p.7-72.

11. Take section4 off section5 and put it aside.

12. Fold the deflection sheave onto section4; à p.7-56.

13. Disconnect the electrical and hydraulic connections between section5 and the main boom: –Electrical connection; à p.7-69, –Hydraulic connection; à p.7-71.

14. Fasten slings to section5 and attach a guide rope:

– à Identification, p.7-3, – à Transport dimensions and weights, p.7-5, – à Slinging points, p.7-4.

15. Disconnect the connection between section5 and the main boom; à p.7-68.

16. Remove section5 from the main boom and put it aside.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

17. Fold the deflection sheave onto section5; à p.7-67.

18. Reeve the hoist rope on to the main boom head, or roll it onto the drum; à GMK5150 / GMK5150L Operating Instructions.

19. Secure section5 in the transport condition; à p.7-5.

20. Secure section4 in the transport condition; à p.7-5.

21. If necessary, move the hoses into the position for working with the main boom; à p.4-6.

22. If necessary, remove the hose drum; à p.4-3.

7.2.10 CHECKLIST: Further rigging work

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisites

–The rigging work specified in the corresponding checklist has been correctly performed.

2. Mount the anemometer and if necessary the air traffic control light; à p.7-64.

3. If necessary, mount the camera; à p.7-66.

4. Reeve the hoist rope on the hook block; à GMK5150 / GMK5150L Operating Instructions.

5. Install the lifting limit switch, attach the lifting limit switch weight and place it around the hoist rope; à p.7-63; à GMK5150 / GMK5150L Operating Instructions.

Integral heavy load lattice extension (ISS) 1.8+2.0m/9.8 + 2.0m 7.2 Checklists for rigging work

6. Disconnect the hand-held control; à GMK5150 / GMK5150L Operating Instructions

7. Check the horizontal alignment of the truck crane and correct, if necessary.

8. Enter the current rigging mode with the rigged ISS; à Setting the RCL, p.7-81.

9. Enter current reeving; à Setting the RCL, p.7-81.

7.3 Rigging work

7.3.1 Securing sections with a guide rope

GRisk of accidents due to sections swinging of their own accord! Always fasten a guide rope to the sections being swung before you unlock or separate the connections. An extra person must keep the guide rope tightly tensioned or you must fasten the guide rope so that the sections cannot slew unintentionally when the necessary connections are unlocked or separated.

Fasten the guide rope to section4

• Attach the guide rope to the rope attachment point (1).

Fasten the guide rope to section5

• Attach the guide rope to the grille (1).

7.3.2 Establishing/separating the Middle 2 connection

Section4 is joined to the main boom at the Middle 2 connection. The connection must be established when only section4 is rigged.

Establishing the connection

• (A) – Remove the pin (2) from the connecting point (1).

• (B) – Turn the attachment plate (4) in the direction of the arrow until the connecting points align.

• Fit the pin (2) into the connecting point (3) and secure it.

• (A) – Swing section4 onto the main boom so that the connecting points on section4 and the Middle 2 connection are aligned.

• (B) – Pull the handle (1) downwards out of the detent latch.

• Turn the handle clockwise as far as possible.

• Allow the handle to slide upwards.

The connection is established when the pin (2) protrudes at the top out of the connecting point.

Disconnecting

• Pull the handle (1) down as far as possible.

• Swing section4 approximately 15° outwards.

• Turn the handle anticlockwise as far as possible.

• Allow the handle (1) to slide upwards into the latch.

• (A) – Remove the pin (2) from the connecting point (1).

• (B) – Turn the attachment plate (4) in the direction of the arrow until the connecting points align.

• Fit the pin (2) into the connecting point (3) and secure it.

7.3.3 Installing/removing section4

GRisk of accidents due to swinging parts! Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–Section4 must be attached to an auxiliary crane. –A guide rope must be attached.

Installing

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2).

• Secure the pins.

Removing

To increase the free space when driving out the lower pins, you can fold the rope guide (4) downwards; à p.7-49.

• Check that the electrical and hydraulic connections have been disconnected.

• If necessary, also remove the hoist rope; à p.7-58.

• Attach section4 to an auxiliary crane.

• Remove the pins (1) from the connecting points (2) and insert them into the clamps (3).

• Secure the pins.

• If necessary, fold the rope guide (4) upwards; à p.7-49.

Folding the rope guide downwards

• (A) – Remove the pins (1) from the connecting points (2) at the left and right sides.

• (B) – Fold the rope guide (3) downwards.

• Insert the pins (1) back into the connecting points (2) at the left and right sides.

• Secure the pins.

Folding the rope guide up

• (A) – Remove the pins (1) from the connecting points (2) at the left and right sides.

• (B) – Fold the rope guide (3) upwards.

• Insert the pins (1) back into the connecting points (2) at the left and right sides.

• Secure the pins.

7.3.4 Establishing/separating connections between section4 and section2

The connection between section4 and section2 when the ISS is rigged from the swing-away lattice. This can occur on the ground or in the transport position.

GRisk of accidents due to swinging parts!

Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

In working position

Prerequisite:

–The swing-away lattice must be in the working position.

–All connections are established according to the checklist.

–The section combination must be attached to an auxiliary crane.

–A guide rope must be attached.

Disconnecting

–The electrical connection between section4 and section2 is disconnected; à p.7-61.

• Remove the pins (1) from the connecting points (2) and insert them into the clamps (3).

• Secure the pins.

On the ground

Connecting

• Derrick section4 so that the connecting points (2) align.

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2) as shown below; à Direction when inserting the pins, p.7-51.

• Secure the pins.

Direction when inserting the pins

If you insert the pins in a different direction than shown here, this can cause problems later when section4 is rigged from the folded swing-away lattice.

1 Pin

2 Pin with double taper

The arrow indicates the direction when inserting the pin.

GRisk of accidents due to falling sections!

Before you break the connection between section4 and the combination of sections you must first support the individual sections so that they cannot fall over.

This prevents the sections falling to the ground after separation and injuring you or other people.

Prerequisites

–The swing-away lattice must be in the transport condition; à p.5-8. –A guide rope must be attached.

–Section2 or section4 must be attached to an auxiliary crane.

Disconnecting

–The electrical connection between section4 and section2 is disconnected; à p.5-93.

• Pack the swing-away lattice so that it cannot fall over.

• Remove the pins (1) from the connecting points (2) and insert them into the clamps (3).

• Secure the pins (1).

• Lift section4 from the swing-away lattice.

Connecting

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2) as shown above; à Direction when inserting the pins, p.7-51.

• Secure the pins.

7.3.5 Connecting/disconnecting the electrical connections –section4/main boom

Connecting the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket(5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the holder (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation and whenslewing.

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the holder (4).

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the holder (4).

• Cover the plug and socket (1) with caps.

7.3.6 Connecting/disconnecting the hydraulic connections –section4 / main boom

Connecting

• Remove the hoses (2) from the holder (3).

• Connect the hoses to the connections (1) (match the markings).

Disconnecting

• Remove the hoses (2) from the connections (1).

• Close the hoses and the connections (1) withthe caps.

• Wind the hoses (2) onto the holder (3).

7.3.7 Folding out / folding in the deflection sheave on section4

GRisk of accidents by exceeding total permissible height!

Fold in the deflection sheaves when the ISS is folded onto the main boom for driving. When the deflection sheave is folded out, the overall height specified for on-road driving is exceeded.

GRisk of crushing!

Always hold the deflection sheave firmly by the handle when removing thepin.

Your fingers may be crushed if you hold the sheave by the side panel.

Folding out

• (A) – Hold the deflection sheave (3) tightly by the handle (1) and pull out the pin (2).

• (B) – Fold the deflection sheave (3) upwards until it is aligned with the connecting point.

• Insert the pin (2) into the connecting point.

• Secure the pin.

Folding in

• (A) – Hold the deflection sheave (4) tightly by the handle (1) and pull out the pin (2).

• (B) – Fold the deflection sheave (4) downwards until it is aligned with the connecting point (3).

• Insert the pin (2) into the connecting point.

• Secure the pin.

7.3.8 Folding out / folding in the head sheave on section4

GRisk of crushing!

Always hold the head sheave by the handle when pulling out the pin. Your fingers may be crushed if you hold the sheave by the side panel.

Folding out

• (A) – Remove the pin (1) from the connecting point.

• Fold the head sheave (3) downwards using the handle until the connection point (2) is aligned.

• (B) – Insert the pin (1) into the connecting point.

• Secure the pin.

Folding in

• (A) – Remove the pin (1) from the connecting point.

• (B) – Manually fold the head sheave (3) upwards by the handle until it is aligned with the connecting point (2).

• Insert the pin (1) into the connecting point.

• Secure the pin.

7.3.9 Fitting/removing the hoist rope – section4

You can use the rigging hook for this à p.3-14.

GRisk of accidents due to falling parts! Always secure the sheaves and rods with retaining pins. This prevents sections coming loose, falling out and causing injuries.

Positioning thehoist rope

• Remove the rods (3).

• Guide the hoist rope over the sheaves (1) and (2).

• Insert the rods (3).

• Secure the rods.

Removing thehoist rope

• Remove the rods (3).

• Guide the hoist rope off the sheaves (1) and(2).

• Insert the rods (3).

• Secure the rods.

7.3.10 Possible reeving methods on the heavy load lattice extension

3 sheave hook block

Reeving

A 4-fall

B 3-fall

1 sheave hook block

Reeving

A 2-fall

B 1-fall

Hook tackle Reeving

A 1-fall

For straight reeving, the hoist rope is attached to the rope attachment point(1).

Reeve the hoist rope; à GMK5150 / GMK5150L Operating Instructions

7.3.11

Connecting/disconnecting the electrical connections –section4/section2

Connecting the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket(5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the holder (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the holder (4).

• Cover the plug and socket (1) with caps.

7.3.12 Installing / removing the lifting limit switch

Installation If only a single lifting limit switch is available you must use the lifting limit switch belonging to the main boom; à GMK5150 / GMK5150L Operating Instructions.

If several lifting limit switches are available, all those lifting limit switches on the main boom from which no lifting limit switch weight is suspended must be overridden; à GMK5150 / GMK5150L Operating Instructions

• Plug the lifting limit switch (4) onto the holder (3).

• Secure the lifting limit switch.

• Fasten the cable so that it does not sag during crane operation and thus might be damaged.

• Insert the plug (2) into the socket (1).

• Install the lifting limit switch weight (5) and lay it around the hoist rope; à GMK5150 / GMK5150L Operating Instructions

• Remove the lifting limit switch weight (5); à GMK5150 / GMK5150L Operating Instructions

• Remove the plug (2) from the socket (1).

• Cover the socket (1) with the cap.

• Remove the lifting limit switch (4) from the holder (3).

• Stow the lifting limit switch away so that it is safe in traffic, or mount it on the main boom; à GMK5150 / GMK5150L Operating Instructions.

7.3.13 Installing / removing the anemometer and air traffic control light

SRisk of damage during transport!

Before transporting the truck crane, always remove the anemometer and the air traffic control light. This prevents them protruding over the specified transport dimensions and prevents the anemometer being damaged by sudden air currents.

Installation The anemometer supplied is used on the ISS.

The anemometer and the air traffic control light – if provided – are located on the same rod.

• Insert the rod (5) into the holder (3) and secure it.

• Remove the cable from the holders (4) and connect

–the anemometer to the socket (2), –the air traffic control light to the socket (1).

• Lay the cables in such a way that they will not be damaged during crane operation.

• Check that the anemometer is able to swing so that it hangs vertically even when the main boom is raised.

Switching the air traffic control light on and off; à GMK5150 / GMK5150L Operating Instructions

Removing the hoist rope

You must remove the rod with the anemometer/air traffic control light before driving on the road.

• Switch off the air traffic control light.

• Remove the plug and close the sockets (1) and (2) with caps.

• Wind the cable on to the holder (4).

• Remove the rod (5) from the holder (3). Stow away the anemometer so that it is safe in traffic; à GMK5150 / GMK5150L Operating Instructions.

7.3.14 Installing / removing the camera

Operating the camera; à GMK5150 / GMK5150L Operating Instructions.

Installation

• Insert the camera (2) into the holder (1) and secure it.

• Insert the plug (4) into the socket (3).

• Lay the cable (5) so that it will not be damaged during crane operation.

Removing the hoist rope

• Take the plug (3) out of the socket (4) and close the socket with the cap.

• Remove the camera (2) from the holder (1) and insert the retaining pin in the holder.

7.3.15 Folding out / folding in the deflection sheave on section5

GRisk of crushing!

Always hold the deflection sheave firmly by the handle when removing the pin.

Your fingers may be crushed if you hold the sheave by the side panel.

Folding out

• (A) – Hold the deflection sheave (2) firmly by the handle (1) and pull out the pin (3).

• (B) – Fold the deflection sheave (2) upwards until the connecting points are aligned.

• Insert the pins (3) into the connecting points.

• Secure the pins.

Folding in

• (A) – Hold the deflection sheave (2) firmly by the handle (1) and pull out the pin (3).

• Fold the deflection sheave (2) downwards until the connecting points align.

• Insert the pins (3) into the connecting points.

• Secure the pins.

7.3.16 Section5/main boom – Establish/separate the connection

GRisk of accidents due to swinging parts! Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–Section5 must be attached to an auxiliary crane. –A guide rope must be attached.

Connecting

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2).

• Secure the pins.

Disconnecting

• Remove the pins (1) from the connecting points (2) and insert them into the clamps (3).

• Secure the pins.

7.3.17 Connecting/disconnecting the electrical connections –section5/main boom

Connecting the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket(5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the holder (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the holder (4).

• Close the plug (2) and the socket (1) with thecaps.

7.3.18

Connecting/disconnecting the hydraulic connections –section5 / main boom

Connecting

• Remove the hoses (2) from the holders (3).

• Remove the caps from the connections (1) and connect the hoses (2) (match the markings).

Disconnecting

• Pull the hoses (2) off the connections (1).

• Close the hoses (2) and the connections (1) with the caps.

• Secure the hoses (2) on the clamp (3) on section5.

7.3.19 Installing/removing section4 on section5

GRisk of accidents due to swinging parts! Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–Section4 must be attached to an auxiliary crane. –A guide rope must be attached.

Installing

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (1).

• Secure the pins.

Removing

• Remove the pins (1) from the connecting points (2) and insert them into the clamps (3).

• Secure the pins.

7.3.20 Connection/disconnecting the electrical connections between section4 and section5

Connecting the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket (5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the holder (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the holder (4).

• Cover the plug and socket (1) with caps.

7.3.21 Connection/disconnecting the hydraulic connection between section4 and section5

Connecting

• Remove the hoses (2) from the holder (3).

• Connect the hoses to the connections (1) (match the markings).

Disconnecting

• Remove the hoses (2) from the connections (1).

• Close the hoses and the connections (1) withthe caps.

• Wind the hoses on to the holder (3) on section4.

7.3.22 Positioning/removing the hoist rope – section5 and section4

You can use the rigging hook for this à p.3-14.

GRisk of accidents due to falling parts! Always secure the sheaves and rods with retaining pins. This prevents sections coming loose, falling out and causing injuries.

• Remove the sheave (5) and rods (4).

• Guide the hoist rope via the deflection sheaves (1) and (2) and over the head sheave(3).

• Fit the sheave and all rods (4).

• Secure the sheave and rods.

Removing the hoist rope

• Remove the sheave (5) and rods (4).

• Take the hoist rope off the head sheave (3) and the deflection sheaves (1) and (2) and place it on the ground on the left side.

• Fit the sheave and all rods (4).

• Secure the sheave and rods.

7.3.23 Derricking cylinder positions

SRisk of damage to the swing-away lattice and add-on parts! Ensure that all necessary connections have been established and separated as specified in the checklist before lowering the ISS. Do not derrick the ISS beyond the position shown by the markings. This prevents damage to the connecting points or add-on parts.

The position (A) is reached when the pointer (4) and the marking (3) line up as shown in the figure above.

When rigging into the working position

Position (A)

The swing-away lattice has been lowered far enough so that the forks (5) can be swung into the hangar elements (6) on the main boom.

When rigging in the transport position

The ISS is raised or lowered far enough so that the attachment plate(2) can be pivoted into the Middle 2 connection (1).

To derrick the ISS with the hand-held control; à p.5-113.

7.4 ISS, derricking

Switching on the derricking gear

After the ignition is switched on, all of the power units will be switched off and the lamps in the corresponding buttons will light up only dimly.

• Press the button (1) once.

–The lamp in button (1) lights up brightly.

–Symbol (2) is green when the derricking gear is switched on.

If the control lever is assigned more than one function, all other power units which are assigned the same control lever movement are switched off.

Raising and lowering

You can adjust the sensitivity of the control levers to suit the operating conditions; à GMK5150 / GMK5150L Operating Instructions

GRisk of accident due to unexpected crane movements! If assigned more than one function, check whether the Derricking control lever function is switched on before you move the control lever for derricking.

This prevents accidents due to unexpected crane movements.

Lowering: Push the control lever to the right – the swing-away lattice will be lowered.

Raising: Push the control lever to the left – the swing-away lattice will be raised.

You can regulate the speed by moving the control lever and changing the engine speed with the accelerator.

HThe maximum derricking speed will automatically be reduced as the system length is increased. If you now reduce the working radius (e.g. by retracting the telescoping), the derricking speed will automatically be increased again.

When derricking the ISS the RCL switches automatically to the values for fixed angle and intermediate angle stated in the lifting capacity table if permissible for the load currently being lifted.

Switching off the derricking gear

If this switchover is not permitted for the load currently raised, derricking will be switched off and a corresponding error message will be generated.

You can adjust the desired engine speed (idling speed) with button (1); à GMK5150 / GMK5150L Operating Instructions.

You can limit the maximum derricking speed; à GMK5150 / GMK5150L Operating Instructions.

• Press the button (1) once.

–The lamp in the button (1) lights up dimly.

–Symbol (2) is red when the derricking gear is switched off. All power units are switched off and the lamps in the corresponding buttons light up only dimly after turning off the ignition.

7.5 Operation with the ISS

The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will need for a rigged or folded ISS. The ISS is referred to as the heavy load lattice extension in the following sections.

7.5.1 Setting the RCL

Input

• Enter the current rigging mode for operation with the heavy load lattice extension into the RCL. Either via the corresponding RCL code in accordance with the lifting capacity table or via the individual components.

If you enter the current rigging mode via the individual components then you must also additionally enter the length of the heavy load lattice extension.

• Input the current reeving on the heavy load lattice extension for the hoist whose hoist rope is reeved on the heavy load lattice extension into the RCL.

HThe lifting capacity for the RCL code is enabled once the telescopic sections are locked.

Shutdown Operation with the heavy load lattice extension is monitored by the RCL. When operating with the heavy load lattice extension, RCL shutdowns may occur for the same reasons as when operating with the main boom; à GMK5150 / GMK5150L Operating Instructions.

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table

–During operation with the heavy load lattice extension

If a hook block (3) is reeved at the main boom, then the displayed current load (1) is influenced by

–The weight of the lifted load (2) and

–the weight of the hook block (3).

–During main boom operation

If a heavy load lattice extension (4) is installed, then the displayed current load (1) is influenced by

–The weight of the lifted load (2) and

–the weight of the heavy load lattice extension (4) and

–the weight of the hook block (3) at the heavy load lattice extension.

HThe lifting capacity tables contain information for operations planning specifying the values which must be subtracted from the specified maximum load bearing capacities for certain rigging modes; à Remarks about working with the hydraulically inclinable heavy load lattice extension.

7.5.2 Derricking, telescoping the main boom

Slewing range of360°

GRisk of accidents if the RCL is overridden! Do not override the RCL when lowering the boom into horizontal position. If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The requirements that must be satisfied before raising, lowering and telescoping the main boom with a rigged heavy load lattice extension are permitted, for a slewing range of 360° are monitored by the RCL. Further information on the permissible angle ranges and lifting capacities is provided in the lifting capacity table; à Rigging tables - lattice extension

If the main boom is set to a steep angle and if the heavy load lattice extension is at 0°, the hook block may hit the main boom. When the minimum permitted working radius has been reached, the RCL will prevent the boom being raised further.

7.5.3 Procedure if permissible wind speeds are exceeded

GRisk of accidents due to excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode. This will prevent the truck crane from overturning due to overload.

• Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed.

• Make sure that you follow the notes on checking the wind speed; à GMK5150 / GMK5150L Operating Instructions.

If the maximum permitted wind speed is exceeded

An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

• Put the truck crane into the rigging mode specified for the current wind speed in the lifting capacity table.

7.5.4 Instructions for turning loads over

à Turning loads over, p.11-1.

7.6

Maintenance

HIf the heavy load lattice extension has been in storage for an extended period of time, perform maintenance work on it no later than when it is next used.

7.6.1

Maintenance

Maintenance work on the HEAVY LOAD LATTICE EXTENSION:

Weekly

Heavy load lattice extension

–Grease the piston rod of the derricking cylinder à p.7-87 M 1

7.6.2

Maintenance

Maintenance work on the HEAVY LOAD LATTICE EXTENSION:

Monthly/after approx. 100 operating hours

Heavy load lattice extension

–Lubricate the pins à p.7-86 M 3

7.6.3

Maintenance

Maintenance work on the HEAVY LOAD LATTICE EXTENSION:

Every three months/after 250 oper. hrs.

Heavy load lattice extension

–Check the sheaves à p.7-87

7.6.4 Maintenance plan M 12

Maintenance work on the HEAVY LOAD LATTICE EXTENSION: Every twelve months/after 1,000 oper. hrs.

Heavy load lattice extension

–Lubricate joints à p.7-89

7.6.5 Description of maintenance work

Pins, sheaves

Grease 1) Designation according to DIN 51502

Specification classification GROVE part no.1)

Grease KP - L2K DIN 51825 00554201

1) à Maintenance manual

Lubricate the pins – Section4

• Lubricate the pins (1).

Check the sheaves– Section4

• Check the deflection sheave (1) and head sheaves (2) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled sheaves replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

Lubricate the pins – Section5

• Lubricate the pins (1).

Check the sheaves– Section5

• Check the deflection sheave (2) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled sheaves replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

Piston rod

Designation

GROVE part no.1)

Lubricant RHUS 2 AF; 1 kg (Apply the grease with a brush)

01929824

03325215 or Spray on Berulub; 0.5 litres (spray-on)

SRisk of damage to the piston rod packing due to rust! Ensure that the piston rod is always kept covered with a layer of grease. This avoids the formation of rust which damages the piston rod packing when lowering the boom.

Perform this maintenance work weekly or at the following points in time:

–After a longer period of storage

–After removal

–After every high-pressure cleaning of the truck crane

–Before the next usage of the crane

–Before putting out of service

• Clean any old grease, dirt particles and rust from the piston rods (1) and if necessary (2).

• Grease the piston rods so that they are evenly coated with a layer of grease.

After every high-pressure cleaning of the truck crane

• Grease the piston rod.

Joints

-

Specification classification GROVE part no.1)

Prerequisites

–The truck crane is secured against unauthorised use; à Maintenance manual or –ISS is removed; à p.7-13.

Lubricate joints

Section4 is fitted with four grease nipples (1).

• Clean the grease nipples (1).

• Press grease into the grease nipples (1) until new grease comes out at the lubricating point.

8

Heavy load lattice extension (SLS) 2.0m/10.0m

8.1 Operations planning

8.1.1 Assembly

SRisk of overturning in other combinations! Assemble the heavy load lattice extension only in the combinations listed as permissible in the lifting capacity table. Other combinations are not monitored by the RCL.

Permissible combinations

1) Designation in the lifting capacity table: Z = length before setting the angle Y = length after setting the angle

8.1.2 Identification

GRisk of accidents if heavy load lattice extensions are interchanged! Install only the heavy load lattice extension that belongs to the truck crane. No other heavy load lattice extensions may be installed.

Section6

The truck crane and the corresponding section6 must be labelled with the same serialnumber (1).

Section5

The truck crane and the corresponding section5 must be labelled with the same serialnumber (1).

8.1.3 Slinging points

GRisk of accidents if used improperly!

Sling the heavy load lattice extension only at the slinging points provided. Use only lifting gear and joining elements of sufficient load bearing capacity.

Section6

The slinging points (1) are marked with the sticker (4).

The information on the weight and the necessary lifting gear is provided on the sticker (3).

The rope attachment point (2) serves as the slinging point for the guide rope.

Section5

The slinging points (1) are marked with stickers (5).

The information on the weight and the necessary lifting gear is provided on the sticker (3) for the derricking design and the sticker (4) for the inclinable design.

The grille (2) serves as the slinging point for the guide rope.

8.1.4 Transport dimensions and weights

8.1.5 Transport condition

Section5

• Check that the heavy lattice load extension is in the transport condition or establish this now, if necessary.

–All pins (1) are secured in the holders.

–The electrical cable is closed with the cap(3).

–The plug (5) has been inserted in the dummy socket.

–The deflection sheave (6) is folded in and secured.

–The section5 must be secured to a suitable support (7).

–With the derricking design, all hoses are closed with the caps (2) and wound onto the clamp (4).

Section6 Removed

• Check that the heavy lattice load extension is in the transport condition or establish this now, if necessary.

–All pins (1) are secured in the holders.

–The plug (6) has been inserted in the dummy socket.

–All sockets (4) are closed with caps.

–The angle position (3) must be set to 0° and the pin must be inserted and secured.

–The chain hoist (2) must be mounted and sufficiently tensioned so that it cannot come loose during transport.

–The rope attachment point (5) is folded upwards.

–Section6 must be secured to a suitable support.

Folded

• Check that the heavy lattice load extension is in the transport condition or establish this now, if necessary.

–The swivel pins (1) must be secured in the connecting points (2) .

–The spring pin (5) is engaged in the clamp(4) and secured.

–All pins (3) are secured in the holders.

–The rope attachment point (1) is folded upwards.

–The angle position (2) must be set to 0° and the pin must be inserted and secured.

–All sockets (3) are closed with caps.

–The plug (4) has been inserted in the dummy socket.

–The chain block (5) has been removed.

8.2 Checklists for rigging work

8.2.1 Overview

The distinction is made between various different procedures.

– Installation and removal

These procedures have to be performed when the lattice extension is being transported separately. The installation and removal of the lattice extension is described.

–Rigging

These procedures must be performed when the lattice extension is being transported on the crane. The changeover between the transport position and the operating position is described.

The following table shows which checklist is applicable for any required rigging work.

Required rigging workChecklist

–SLS Install–In operating position CHECKLIST: SLS Installing 2.0m – into the working position, p.8-8

–In transport position CHECKLIST: SLS Installing 2.0m – into the transport position, p.8-11

–SLS Removing–From operating position CHECKLIST: SLS Removing 2.0m – from the working position, p.8-12

SLS 2.0m

SLS 10.0m

–From transport position CHECKLIST: SLS Removing 2.0m – from transport position, p.8-15

–SLS rigging–In operating position CHECKLIST: SLS Rigging 2.0m – into the working position, p.8-17

–In transport position CHECKLIST: SLS Rigging 2.0m – into the transport position, p.8-20

–SLS Install–In operating position CHECKLIST: SLS Installing 10.0m, p.8-23

–SLS Removing–From operating position CHECKLIST: SLS Removing 10.0m, p.8-27

8.2.2 CHECKLIST: SLS Installing 2.0m – into the working position

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites à Identification, p.8-2 à Transport dimensions and weights, p.8-4 à Slinging points, p.8-3 à Possible reeving methods on the heavy load lattice extension, p.8-41 à GMK5150 / GMK5150L Operating Instructions

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

–An auxiliary crane must be available.

2. Check the transport condition of section6; à p.8-5.

3. –Fasten slings to section6 and attach a guide rope.

–Lift section6 into position in front of the main boom.

4. –Establish a mechanical connection between section6 and the main boom; à p.8-31.

–Remove the lifting gear and the guide rope.

5. Establish electrical connection between section6 and the main boom; à p.8-37.

6. Adjust the angle position, if necessary; à p.8-39.

7. Place the hoist rope on section6; à p.8-40.

8. Reeve the hook block.

9. –Install the lifting limit switch; à p.8-43. –Attach the lifting limit switch weight; à GMK5150 / GMK5150L Operating Instructions.

10. Mount the anemometer and if necessary the air traffic control light; à p.8-44.

Heavy load lattice extension (SLS) 2.0m/10.0m 8.2 Checklists for rigging work

11. If necessary, mount the camera; à p.8-46.

12. Check the horizontal alignment of the truck crane and correct it if necessary; à GMK5150 / GMK5150L Operating Instructions.

13. Enter the current rigging mode with the rigged heavy load lattice extension; à p.8-57.

14. Enter current reeving; à p.8-41.

8.2.3 CHECKLIST: SLS Installing 2.0m – into the transport position

H This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites à Identification, p.8-2 à Transport dimensions and weights, p.8-4 à Slinging points, p.8-3

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

–An auxiliary crane must be available.

2. Check the transport condition of section6; à p.8-5.

3. –Fasten slings to section6 and attach a guide rope.

–Lift section6 into position at the main boom.

4. –Establish a mechanical connection between section6 and the main boom; à p.8-33.

–Remove the lifting gear and the guide rope.

8.2.4 CHECKLIST: SLS Removing 2.0m – from the working position

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions

–An auxiliary crane must be available.

2. Remove the anemometer and if necessary the air traffic control light; à p.8-45.

3. If necessary, remove the camera; à p.8-46.

4. –Remove the lifting limit switch weight.; à GMK5150 / GMK5150L Operating Instructions

–Remove the lifting limit switch; à p.8-43.

5. Set down the hook block and unreeve the hoist rope; à GMK5150 / GMK5150L Operating Instructions à Identification, p.8-2 à Transport dimensions and weights, p.8-4 à Slinging points, p.8-3

6. Remove the hoist rope from section6; à p.8-40.

7. Set 0° angle, if necessary; à p.8-39.

8. Disconnect the electrical connection between section6 and the main boom; à p.8-38.

9. Fasten slings to section6 and attach a guide rope.

10. Disconnect the connection between section6 and the main boom; à p.8-33.

Heavy load lattice extension (SLS) 2.0m/10.0m

8.2 Checklists for rigging work

11. Remove section6 from the main boom and put it aside.

12. Check the transport condition of section6; à p.8-5.

13. Reeve the hoist rope on to the main boom head, or roll it onto the drum; à GMK5150 / GMK5150L Operating Instructions.

8.2.5 CHECKLIST: SLS Removing 2.0m – from transport position

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites à Identification, p.8-2 à Transport dimensions and weights, p.8-4 à Slinging points, p.8-3

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

–Section6 is folded up against the side of the main boom.

–An auxiliary crane must be available.

2. Fasten slings to section6 and attach a guide rope.

3. Disconnect the connection between section6 and the main boom; à p.8-31.

Heavy load lattice extension (SLS) 2.0m/10.0m 8.2 Checklists for rigging work

4. Remove section6 from the main boom and put it aside.

5. Check the transport condition of section6; à p.8-5.

6. Reeve the hoist rope on to the main boom head, or roll it onto the drum; à GMK5150 / GMK5150L Operating Instructions.

8.2.6 CHECKLIST: SLS Rigging 2.0m – into the working position

H This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

2. Fasten the guide rope to section6; à p.8-3.

3. –Bring section6 into the working position; à p.8-35. –Remove the guide rope.

4. Establish electrical connection between section6 and the main boom; à p.8-37.

Heavy load lattice extension (SLS) 2.0m/10.0m

8.2 Checklists for rigging work à Possible reeving methods on the heavy load lattice extension, p.8-41 à GMK5150 / GMK5150L Operating Instructions

5. Adjust the angle position, if necessary; à p.8-39.

6. Place the hoist rope on section6; à p.8-40.

7. Reeve the hook block.

8. –Install the lifting limit switch; à p.8-43. –Attach the lifting limit switch weight; à GMK5150 / GMK5150L Operating Instructions.

9. Mount the anemometer and if necessary the air traffic control light; à p.8-44.

10. If necessary, mount the camera; à p.8-46.

11. Check the horizontal alignment of the truck crane and correct it if necessary; à GMK5150 / GMK5150L Operating Instructions

12. Enter the current rigging mode with the rigged heavy load lattice extension; à p.8-57.

13. Enter current reeving; à p.8-41.

8.2.7 CHECKLIST: SLS Rigging 2.0m – into the transport position

HThis checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisites

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

2. Remove the anemometer and if necessary the air traffic control light; à p.8-44.

3. If necessary, remove the camera; à p.8-46.

4. –Remove the lifting limit switch weight.; à GMK5150 / GMK5150L Operating Instructions

–Remove the lifting limit switch; à p.8-43.

5. Set down the hook block and unreeve the hoist rope; à GMK5150 / GMK5150L Operating Instructions

Heavy load lattice extension (SLS) 2.0m/10.0m

8.2 Checklists for rigging work

11. Check the transport position of section6; à p.8-6.

12. Reeve the hoist rope on to the main boom head, or roll it onto the drum; à GMK5150 / GMK5150L Operating Instructions.

8.2.8 CHECKLIST: SLS Installing 10.0m

H This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites à Identification, p.8-2 à Transport dimensions and weights, p.8-4 à Slinging points, p.8-3 à Identification, p.8-2 à Transport dimensions and weights, p.8-4 à Slinging points, p.8-3

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

–An auxiliary crane must be available.

2. Check the transport condition of section5; à p.8-5.

3. Fold out the deflection sheave on section5 and secure it; à p.8-47.

4. –Fasten slings to section5 and attach a guide rope. –Lift section5 into position in front of the main boom.

5. –Establish a mechanical connection between section5 and the main boom; à p.8-48.

–Remove the lifting gear and the guide rope.

6. Establish electrical connection between section5 and the main boom; à p.8-49.

7. Check the transport condition of section6; à p.8-5.

8. –Fasten slings to section6 and attach a guide rope. –Lift section6 up in front of section5.

9. –Establish the connection between section6 and section5; à p.8-51.

–Remove the lifting gear and the guide rope.

10. Establish the electrical connection between section6 and section5; à p.8-52.

11. Adjust the angle position, if necessary; à p.8-39.

12. Lay the hoist rope on to section5 and section6; à p.8-54.

13. Reeve the hook block. à Possible reeving methods on the heavy load lattice extension, p.8-41 à GMK5150 / GMK5150L Operating Instructions

14. –Install the lifting limit switch; à p.8-43. –Attach the lifting limit switch weight; à GMK5150 / GMK5150L Operating Instructions.

15. Mount the anemometer and if necessary the air traffic control light; à p.8-44.

16. If necessary, mount the camera; à p.8-46.

Heavy load lattice extension (SLS) 2.0m/10.0m

8.2 Checklists for rigging work

17. Check the horizontal alignment of the truck crane and correct it if necessary; à GMK5150 / GMK5150L Operating Instructions

18. Enter the current rigging mode with the rigged heavy load lattice extension; à p.8-57.

19. Enter current reeving; à p.8-41.

8.2.9 CHECKLIST: SLS Removing 10.0m

H This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there.

1. Prerequisites

–The truck crane must be supported on outriggers; à GMK5150 / GMK5150L Operating Instructions.

–The appropriate counterweight for the crane operation must be rigged; à GMK5150 / GMK5150L Operating Instructions.

–The main boom must be completely retracted and lowered into the horizontal position; à GMK5150 / GMK5150L Operating Instructions.

–An auxiliary crane must be available.

2. Remove the anemometer and if necessary the air traffic control light; à p.8-44.

3. If necessary, remove the camera; à p.8-46.

4. –Remove the lifting limit switch weight.; à GMK5150 / GMK5150L Operating Instructions

–Remove the lifting limit switch; à p.8-43.

Heavy load lattice extension (SLS) 2.0m/10.0m 8.2 Checklists for rigging work

5. Set down the hook block and unreeve the hoist rope; à GMK5150 / GMK5150L Operating Instructions à Identification, p.8-2 à Transport dimensions and weights, p.8-4 à Slinging points, p.8-3 à Identification, p.8-2 à Transport dimensions and weights, p.8-4 à Slinging points, p.8-3

6. Remove the hoist rope from section5 and section6; à p.8-54.

7. Set 0° angle, if necessary; à p.8-39.

8. Disconnect the electrical connection between section6 and section5; à p.8-53.

9. Fasten slings to section6 and attach a guide rope.

10. Disconnect the connection between section6 and section5; à p.8-51.

11. Take section6 off section5 and put it aside.

12. Check the transport condition of section6; à p.8-5.

13. Disconnect the electrical connection between section5 and the main boom; à p.8-50.

14. Fasten slings to section5 and attach a guide rope.

15. Disconnect the connection between section5 and the main boom; à p.8-48.

16. Remove section5 from the main boom and put it aside.

Heavy load lattice extension (SLS) 2.0m/10.0m

8.2 Checklists for rigging work

17. Fold in and secure the deflection sheave at section5; à p.8-47.

18. Check the transport condition of section5; à p.8-5.

19. Reeve the hoist rope on to the main boom head, or roll it onto the drum; à GMK5150 / GMK5150L Operating Instructions.

8.3 Description of the rigging work

8.3.1 Section6/main boom– Establish/separate the connection in the working position

GRisk of accidents due to swinging parts!

Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–Section6 must be attached to an auxiliary crane. –A guide rope must be attached.

Connecting

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and plug them into the connecting points.

• Secure the pins.

• Remove the swivel pins (1) from the holders(3) and plug them into the connecting points (2).

• Secure the swivel pins.

Disconnecting

• Remove the pins (1) from the connecting points (2) and insert them into the clamps(3).

• Secure the pins.

• Remove the swivel pins (1) from the connecting points (2) and plug them into the clamps (3).

• Secure the swivel pins.

8.3.2

Section6/main boom – Establish/separate the connection in the transport position

GRisk of accidents due to swinging parts! Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–Section6 must be attached to an auxiliary crane. –A guide rope must be attached.

Connecting

• Align the connecting points (2).

• Remove the swivel pins (1) from the holders(3) and plug them into the connecting points (2).

• Secure the swivel pins.

• (A) – Remove the linchpin from the spring pin (1).

• (B) – Swing section6 onto the main boom until the spring pin (1) engages in the clamp(2).

• Secure the spring pin (1) with the linchpin.

Disconnecting

• (A) – Remove the linchpin from the spring pin (1).

• (B) – Pull the spring pin (1) out of the clamp(2) and swing section6 somewhat outwards.

• Secure the spring pin (1) with the linchpin.

• Remove the swivel pins (1) from the connecting points (2) and plug them into the clamps (3).

• Secure the swivel pins.

8.3.3 Bringing section6 from the transport position into the working position

GRisk of accidents due to section6 falling down! Ensure that the swivel pins are inserted. This prevents section6 falling down and causing injuries.

–A guide rope must be attached.

The swivel pins (1) must be secured in the connecting points (2).

• (A) – Remove the linchpin from the spring pin (3).

• Pull the spring pin (3) out of the clamp (4) and swing section6 somewhat outwards.

• (B) – Secure the spring pin (3) with the linchpin.

• Swing section6 in front of the main boom until the connecting points (2) are aligned.

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2).

• Secure the pins.

8.3.4 Bringing section6 into the transport position

GRisk of accidents due to section6 falling down!

Before you remove the pins from the connecting points, make sure that the swivel pins are inserted. This prevents section6 falling down and causing injuries.

–A guide rope must be attached.

The swivel pins (1) must be secured in the connecting points (2).

• Remove the pins (3) from the connecting points (5) and insert them into the clamps(4).

• Secure the pins.

• (A) – Remove the linchpin from the spring pin (1).

• (B) – Swing section6 onto the main boom until the spring pin (1) engages in the clamp(2).

• Secure the spring pin (1) with the linchpin.

8.3.5 Section6/main boom – Establish/separate the electrical connections

Connecting the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket(5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the holder (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Heavy load lattice extension (SLS) 2.0m/10.0m

8.3 Description of the rigging work

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the holder (4).

• Close the plug (2) and the socket (1) with thecaps.

8.3.6 Section6 – Setting the angle

SRisk of damage when the chain hoist is installed!

Always remove the chain hoist before starting crane operation. This prevents overloading of the chain hoist and prevents damage resulting from a collision between chain hoist components and the crane.

SDanger for incorrectly set 40° angle!

When setting the 40° angle, you must first reconfigure the pins before lowering the heavy load lattice extension with the chain hoist. If the pins are inserted after lowering the heavy load lattice extension then the angle is greater than 40°.

• Attach the chain hoist supplied (2) at the slinging points (1) and (3).

• Use the chain hoist to relieve the load on the pins (5).

For a 0° angle

• (B) – Remove the pin (5) from the connecting point (6).

• (A) – Lift the heavy load lattice extension right up to the stop.

• Insert the pin (5) into the connecting point(4).

• Secure the pin.

For a 40° angle

• (A) – Insert the pin (5) from the connecting point (4) into the connecting point (6).

• (B) – Lower the heavy load lattice extension right down to the stop.

• Secure the pin.

For crane operation

• Loosen the chain hoist.

• Remove the chain hoist.

8.3.7 Section6 – Fitting/removing the hoist rope

GRisk of accidents due to falling parts! Always secure the sheaves and rods with retaining pins. This prevents sections coming loose, falling out and causing injuries.

Positioning the hoist rope

• Remove the rod (2).

• Pull out the rod (4) and fold the rope attachment point (5) downwards.

• Guide the hoist rope over the sheaves (1) and (3).

• Insert the rods (2) and (4).

• Secure the rods.

Removing the hoist rope

• Remove the rods (2) and (4).

• Remove the hoist rope from the sheaves (1) and (3).

• Fold the rope attachment point (5) upwards and secure it with the rod (4).

• Insert the rod (2).

• Secure the rods.

8.3.8 Possible reeving methods on the heavy load lattice extension

3 sheave hook block

Reeving

A 4-fall

B 3-fall

1 sheave hook block

Reeving

A 3-fall

B 2-fall

C 1-fall

Heavy load lattice extension (SLS) 2.0m/10.0m

8.3 Description of the rigging work

Hook tackle Reeving

A 1-fall

For straight reeving, the hoist rope is attached to the rope attachment point(1).

Reeve the hoist rope; à GMK5150 / GMK5150L Operating Instructions

8.3.9 Installing / removing the lifting limit switch

Installation If only a single lifting limit switch is available you must use the lifting limit switch belonging to the main boom; à GMK5150 / GMK5150L Operating Instructions.

If several lifting limit switches are available, all those lifting limit switches on the main boom from which no lifting limit switch weight is suspended must be overridden; à GMK5150 / GMK5150L Operating Instructions

• Plug the lifting limit switch (4) onto the holder (3).

• Secure the lifting limit switch.

• Lay the cable so that it will not be damaged during crane operation.

• Insert the plug (2) into the socket (1).

• Install the lifting limit switch weight (5) and lay it around the hoist rope; à GMK5150 / GMK5150L Operating Instructions.

• Remove the lifting limit switch weight (5); à GMK5150 / GMK5150L Operating Instructions

• Remove the plug (2) from the socket (1).

• Cover the socket (1) with the cap.

• Remove the lifting limit switch (4) from the holder (3).

• Stow the lifting limit switch so that it is safe in traffic, or install it on the main boom; à GMK5150 / GMK5150L Operating Instructions

8.3.10 Installing / removing the anemometer and air traffic control light

SRisk of damage during transport!

Before transporting the truck crane, remove the anemometer and the air traffic control light.

This prevents them protruding over the specified transport dimensions and prevents the anemometer being damaged by sudden air currents.

Installation You must install the anemometer for operation with the heavy load lattice extension.

The anemometer and the air traffic control light – if provided – are located on the same rod.

• Insert the rod (5) into the holder (3) and secure it.

• Remove the cable from the holders (4) and connect

–the anemometer to the socket (1),

–the air traffic control light to the socket (2).

• Lay the cables in such a way that they will not be damaged during crane operation.

• Check that the anemometer is able to swing so that it hangs vertically even when the main boom is raised.

Switching the air traffic control light on and off; à GMK5150 / GMK5150L Operating Instructions.

Removing the hoist rope

You must remove the rod with the anemometer/air traffic control light before driving on the road.

• Switch off the air traffic control light.

• Remove the plug and close the sockets (1) and (2) with caps.

• Wind the cable on to the holder (4).

• Remove the rod (5) from the holder (3).

• Stow away the anemometer so that it is safe in traffic; à GMK5150 / GMK5150L Operating Instructions.

8.3.11 Installing / removing the camera

Operating the camera; à GMK5150 / GMK5150L Operating Instructions.

Installation

• Insert the camera (2) into the holder (1) and secure it.

• Insert the plug (3) into the socket (4).

• Lay the cable (5) so that it will not be damaged during crane operation.

Removing the hoist rope

• Remove the plug (3) from the socket (4).

• Close the plug (3) and the socket (4) with the caps.

• Remove the camera (2) from the holder (1) and insert the retaining pin in the holder.

8.3.12 Section5 – Folding out/folding in the deflection sheave

GRisk of crushing!

Always hold the deflection sheave firmly by the handle when removing the pin.

Your fingers may be crushed if you hold the sheave by the side panel.

Folding out

• (A) – Hold the deflection sheave (2) firmly by the handle (1) and pull out the pin (3).

• (B) – Fold the deflection sheave (2) upwards until the connecting points line up.

• Insert the pins (3) into the connecting points.

• Secure the pins.

Folding in

• (A) – Hold the deflection sheave (2) firmly by the handle (1) and pull out the pin (3).

• (B) – Fold the deflection sheave (2) downwards until the connecting points align.

• Insert the pins (3) into the connecting points.

• Secure the pins.

8.3.13

Section5/main boom – Establish/separate the connection

GRisk of accidents due to swinging parts! Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–Section5 must be attached to an auxiliary crane. –A guide rope must be attached.

Connecting

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2).

• Secure the pins.

Disconnecting

• Remove the pins (1) from the connecting points (2) and insert them into the clamps(3).

• Secure the pins.

8.3.14

Section5/main boom – Establish/separate the electrical connections

Connecting the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket(5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the holder (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Heavy load lattice extension (SLS) 2.0m/10.0m

8.3 Description of the rigging work

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the holder (4). Close the plug (2) and the socket (1) with the caps.

8.3.15

Section6/section5 – Establishing/separating the connection

GRisk of accidents due to swinging parts!

Always secure the sections with a guide rope from the ground before establishing or separating connections. This prevents you from being crushed or caught by swinging sections.

–Section6 must be attached to an auxiliary crane. –A guide rope must be attached.

Connecting

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (2).

• Secure the pins.

Disconnecting

• Remove the pins (1) from the connecting points (2) and insert them into the clamps(3).

• Secure the pins.

8.3.16

Section6/section5 – Establishing/separating the electrical connections

Connecting the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket (5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the holder (4).

• Insert the plug (2) into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) onto the holder (4).

• Close the plug (2) and the socket (1) with thecaps.

8.3.17

Positioning the hoist rope

Section6/section5 – Fitting/removing the hoist rope

GRisk of accidents due to falling parts! Always secure the sheaves and rods with retaining pins. This prevents sections coming loose, falling out and causing injuries.

• Remove the rod and sheave (4).

• Remove the rod (5).

• Pull out the rod (6) and fold the rope attachment point (7) downwards.

• Guide the hoist rope via the deflection sheaves (1) and (2) and over the head sheave(3).

• Insert the rods (5) and (6).

• Install the sheave and the rod (4).

• Secure the rods.

Removing the hoist rope

• Remove the rod and sheave (4).

• Remove the rods (5) and (6).

• Remove the hoist rope from the head sheave (3) and the deflection sheaves (2) and (1).

• Lay the hoist rope down on the ground at the left-hand side or roll it onto the drum up to the main boom head or up to the rope drum.

• Fold the rope attachment point (7) upwards and secure it with the rod (6).

• Insert the rod (5).

• Install the sheave and the rod (4).

• Secure the rods.

Heavy load lattice extension (SLS) 2.0m/10.0m

8.3 Description of the rigging work

Blank page

8.4 Operation with the heavy load lattice extension

8.4 Operation with the heavy load lattice extension

The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will need for a rigged or folded heavy load lattice extension.

8.4.1 Setting the RCL

Input

• Enter the current rigging mode for operation with the heavy load lattice extension. Either via the corresponding RCL code in accordance with the lifting capacity table or via the individual components.

When you input the current rigging mode for the individual components you must also input

–the length of the heavy load lattice extension and –the angle of the heavy load lattice extension.

• Input the current reeving on the heavy load lattice extension for the hoist whose hoist rope is reeved on the heavy load lattice extension into the RCL.

HThe lifting capacity for the RCL code is enabled once the telescopic sections are locked.

Heavy load lattice extension (SLS) 2.0m/10.0m

8.4 Operation with the heavy load lattice extension

Shutdown Operation with the heavy load lattice extension is monitored by the RCL. When operating with the heavy load lattice extension, RCL shutdowns may occur for the same reasons as when operating with the main boom; à GMK5150 / GMK5150L Operating Instructions.

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table

–During operation with the heavy load lattice extension

If a hook block (3) is reeved at the main boom, then the displayed current load (1) is influenced by

–The weight of the lifted load (2) and

–The weight of the hook block (3).

–During main boom operation

If a heavy load lattice extension (4) is installed, then the displayed current load (1) is influenced by

–The weight of the lifted load (2) and

–The weight of the hook block (3) and

–The weight of the heavy load lattice extension (4).

HThe lifting capacity tables contain information for operations planning specifying the values which must be subtracted from the specified maximum load bearing capacities for certain rigging modes; à Remarks about working with the heavy load lattice extension.

8.4.2 Derricking, telescoping the main boom

Slewing range of360°

GRisk of accidents if the RCL is overridden! Do not override the RCL when lowering the boom into horizontal position. If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The requirements that must be satisfied before the raising, lowering and telescoping of the main boom with rigged heavy load lattice extension are permitted, for a slewing range of 360° are monitored by the RCL. Further information on the permissible angle ranges and lifting capacities is provided in the lifting capacity table; à Rigging tables - lattice extension

If the main boom is set to a steep angle and if the heavy load lattice extension is at 0°, the hook block may hit the main boom. When the minimum permitted working radius has been reached, the RCL will prevent the boom being raised further.

8.4.3 Procedure if permissible wind speeds are exceeded

GRisk of accidents due to excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode. This will prevent the truck crane from overturning due to overload.

• Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed.

• Make sure that you follow the instructions for checking the wind speed; à Lifting capacity table and GMK5150 / GMK5150L Operating Instructions.

If the maximum permitted wind speed is exceeded

An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

• Put the truck crane into the rigging mode specified for the current wind speed in the lifting capacity table.

8.4.4 Instructions for turning loads over

à Turning loads over, p.11-1.

8.5

H

Maintenance

If the heavy load lattice extension has been in storage for an extended period of time, perform maintenance work on it no later than when it is next used.

8.5.1

Maintenance plan M 1

Maintenance work on the HEAVY LOAD LATTICE EXTENSION:

Monthly/after approx. 100 operating hours

Heavy load lattice extension

M 1

–Lubricate the pins on section5 à p.8-62

–Lubricate the pins on section6 à p.8-63 M 3

8.5.2

Maintenance plan M 3

Maintenance work on the HEAVY LOAD LATTICE EXTENSION: every three months/after 250 oper. hrs.

Heavy load lattice extension

–Check the sheaves on section5 à p.8-62

–Check the sheaves on section6 à p.8-63

8.5.3

Maintenance plan M 12

Maintenance work on the HEAVY LOAD LATTICE EXTENSION: every 12 months/after 1,000 operating hours

Heavy load lattice extension

M 12

–Lubricate the spring pins à p.8-63

8.5.4 Description of maintenance work

Grease 1) Designation according to DIN 51502

Specification classification GROVE part no.1)

Grease KP - L2K DIN 51825 00554201

1) à Maintenance manual

Prerequisites

–The truck crane must be secured to prevent unauthorised use; à Maintenance manual. or

–The heavy load lattice extension is removed; à p.8-31.

Section5

Lubricate the pins

• Grease the pins (1).

Check the sheaves

• Check the deflection sheave (2) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled sheaves replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

Section6

Lubricate the spring pins

• Clean the grease nipple (1).

• Press grease into the grease nipple (1) until new grease comes out at the lubricating point.

Lubricate the pins

• Grease the pins (1).

Check the sheaves

• Check the deflection sheave (2) and head sheaves (3) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled sheaves replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.