PDF Operating Manual Grove GMK 5250L Crane Lattice Extension - 4 MB
This is the official operating manual specifically for the lattice extension of the Grove GMK 5250L mobile crane.
It contains critical safety information, load charts, and assembly/disassembly procedures for the extension.
Proper use of this manual is mandatory for ensuring safe lifting operations.
Crane operators and riggers must be familiar with its contents before use.
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Lattice extension
operating manual
3 302 450 en
22/02/2016
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2
2 Basic safety instructions
2.1 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
2.2 Safety instructions for working with a lattice extension . . . . . . . . . . . . . . . . . . . 2 - 2
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Operating elements
3.1 On the lattice extension
3.1.4 Section 2 control unit
Operating elements
1 Function buttons
Button combinations
There are two button combinations; buttons
that are engaged are shown in black:
A Raise swing-away lattice
B Lower swing-away lattice
– Function on
Press the required button combination.
– (C) – Function off
C Release one or both the buttons.
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Lattice extension operating manual 3 302 450 en 3-5
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Operating elements
3.3 On the hand-held control
3.3.1 Connecting hand-held control
With the hand-held control
Derricking the swing-away lattice is enabled at
the sockets (1) and (2).
Connection to the socket (2) is not suitable
for rigging since you cannot see the folded
swing-away lattice from this point.
This socket (2) is intended for emergency
operation.
• Connect the hand-held control to the
socket (1).
Connecting the à Operating manual GMK5250L.
hand-held control
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Lattice extension operating manual 3 302 450 en 3 - 15
GMK 5250L
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Rigging work on the main boom
4.2 Rigging work on the hose reel
Attaching the hoses
• Loosen the hinged pins (3) and fold up the
guide rollers (4).
• Remove the hoses from the clamp (1) and
fasten them to the clamp (2).
• Fold down the guide rollers (4) and secure
them with the linchpins (3).
Fastening the connections
• (A) – Remove the retaining pins from the
securing bolts (1).
• (B) – Place the connection plate (2) on the
bolts (1).
• Insert the retaining pins into the bolts (1).
s
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Swing-away lattice
5.2 Operations planning
Section
combination
For section combinations, the slinging points
and the information on weight and required
lifting gear are specified on the stickers (1)
and (2).
Example
For the section combination, section 1 is
folded onto section 2, and section 2 is
mounted in front of section 4.
The sticker (6) shows:
– The weight
– The slinging points 3 and 5
– The manner in which the lifting gear must
be attached to the slinging point (7).
Slinging points 3 and 5 on the swing-away
lattice are labelled with stickers having the
corresponding numerals.
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Swing-away lattice
5.3 Checklists for rigging work
5.3.2 CHECKLIST: Installing the swing-away lattice – into the
working position
H
This checklist is not equivalent to the complete operating instructions.
There are accompanying operating instructions which are indicated by
cross-references.
Observe the warnings and safety instructions specified there!
1. Prerequisite
– The truck crane is on outriggers and the superstructure is turned to
à
the side or to the rear; Operating manual GMK5250L.
– The appropriate counterweight for the crane operation must be
rigged;à Operating manual GMK5250L.
– The main boom must be completely retracted and lowered into the
horizontal position;àOperating manual GMK5250L.
– An auxiliary crane must be available.
2. Mount the hose drum; à p. 4 - 3.
3. Check that the locking device has been released; à p. 4 - 5.
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Swing-away lattice
5.3 Checklists for rigging work
9. Unlock the driver at the front connection; à p. 5 - 79.
10. Fully extend the swivel ram; à p. 5 - 77.
11. Bring the swivel ram into the locked position; à p. 5 - 80.
12. Establish the hydraulic/electrical connections on the main boom:
– Hydraulic connection; à p. 5 - 105,
– Electrical connection; à p. 5 - 108.
13. Sling lifting gear to the swing-away lattice and attach guide ropes:
– à Identification, p. 5 - 3,
– à Transport dimensions and weights, p. 5 - 6,
– à Slinging points, p. 5 - 4.
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Swing-away lattice
5.3 Checklists for rigging work
– Separate the connections on the right and left of the main boom head;
à p. 5 - 88.
– Remove the lattice extension hand-held control, à p. 3 - 4.
11. Disconnect the hydraulic and electrical connections to the main boom:
– Hydraulic connection; à p. 5 - 105,
– Electrical connection; à p. 5 - 108.
12. If mechanical locking is in use
– Disconnecting the slewing connection; à p. 5 - 87.
– Separate the connections on the right and left of the main boom head;
à p. 5 - 91.
s
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Swing-away lattice
5.3 Checklists for rigging work
19. Extend the swivel ram; à p. 5 - 77.
20. Unlock the swivel ram; à p. 5 - 80.
Hold section 2 with a guide rope when doing this.
21. Using the guide rope, swing section 2 in front of the main boom head;
à p. 5 - 103.
22. Establishing and securing the connections at the right and left of the
main boom head:
– With hydraulic locking pins; à p. 5 - 88,
– With mechanical locking pins; à p. 5 - 91.
23. Establish the hydraulic/electrical connections on the main boom:
– Hydraulic connection; à p. 5 - 105,
– Electrical connection; à p. 5 - 108.
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Swing-away lattice
5.3 Checklists for rigging work
10. Fasten the guide ropes to section 2.
11. Unlock the front connection; à p. 5 - 79.
12. Check that the extension cylinder is fully extended; à p. 5 - 75.
13. Fully extend the swivel ram; à p. 5 - 77.
14. Lock the swivel ram; à p. 5 - 80.
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Swing-away lattice
5.3 Checklists for rigging work
19. Fully extend the swivel ram; à p. 5 - 77.
20. Lock the swivel ram; à p. 5 - 80.
21. Checks at the rear connection.
– The connection is secured in the rear position by the pin (1);
à p. 5 - 82.
– The pin (2) must be secured in the holder; à p. 5 - 83.
22. Check that the slewing connection is established and secured:
– With hydraulic locking pins; à p. 5 - 84,
– With mechanical locking pins; à p. 5 - 87.
23. Separating the connections on the right and left of the main boom
head:
– With hydraulic locking pins; à p. 5 - 88,
– With mechanical locking pins; à p. 5 - 91.
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Swing-away lattice
5.4 Rigging work
5.4.4 Extending/retracting the swivel ram
The swivel ram can slew the swing-away lattice.
When rigging
Retracting the swivel ram pulls the swing-away
lattice onto the console on the main boom.
Extending the swivel ram pushes the swing-
away lattice away from the console on the
main boom.
When working with the main boom
The swing-away lattice is slewed
automatically; à p. 5 - 132.
(A) – The swing-away lattice is swung
outwards before telescoping out so that the
telescopic sections can move past the swing-
away lattice.
(B) – The swing-away lattice is swung onto the
main boom and into the transport position
after telescoping in.
S
Risk of damage to connecting points!
Ensure that all necessary connections have been established and separated
as specified in the checklist before moving the swivel ram.
This prevents the connecting points from being damaged or torn off.
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Swing-away lattice
5.4 Rigging work
5.4.11 Establishing/separating the slewing connection – mechanical
locking
G
Risk of accidents if used improperly!
Attach slings to the swing-away lattice only at the designated slinging
points. Use only sling gear and joining elements of sufficient load bearing
capacity.
Connecting
A guide rope must be attached.
• Sling the swing-away lattice on an auxiliary
crane if necessary.
• Align the connecting points (1).
• Remove the pins (2) from the clamps (3) and
insert them into the connecting points (1).
• Secure the pins.
• Disconnect the guide rope and the lifting
gear.
G
There is a risk of accidents due to the swing-away lattice falling.
Ensure that the swing-away lattice is slung on an auxiliary crane or
attached to the main boom before separating the slewing connection. This
prevents the swing-away lattice from falling down and injuring or killing
you or other persons.
Separating
A guide rope must be attached.
• Sling the swing-away lattice on an auxiliary
crane if necessary.
• Remove the pins (2) from the connecting
points (1) and insert them into the
clamps (3).
• Secure the pins.
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Swing-away lattice
5.4 Rigging work
Section 1 -
section 2
Connecting
• Attach section 1 to an auxiliary crane.
• Align the connecting points (1).
• Remove the pins (3) from the clamps (2) and
insert them into the connecting points (1).
• Secure the pins.
H
Set the lattice extension down on the ground to relieve the load on the pins.
Use the control unit in section 2 for this.
Separating
A guide rope must be attached.
• Attach section 1 to an auxiliary crane.
• Remove the pins (3) from the connecting
points (1) and insert them into the
clamps (2).
• Secure the pins.
• Lift section 1 off from section 2.
H
One you have lifted sections 1 and 2 together you can then separate
section 1 from section 2 on the ground. To do this you must first disconnect
the electrical connections between the sections.
G
Risk of accidents due to falling sections!
Before you separate section 1 from section 2 on the ground you must first
support the individual sections so that they cannot fall over.
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In this way you avoid that the sections fall to the ground after they have
been separated, and injure you or other people.
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Swing-away lattice
5.4 Rigging work
5.4.21 Establishing/disconnecting electrical connections
to the swing-away lattice
G
Risk of crushing due to movement of swing-away lattice
Always lock the swing-away lattice or secure it with the guide ropes to
prevent it from swinging before you start establishing or disconnecting
electrical connections.
This prevents the swing-away lattice from swinging and crushing you.
Depending on the swing-away lattice A - D being used, you must establish/
separate different electrical connections1 6
to for sections 1 4
to .
1 Section 4 - Main boom à p. 5 - 108
2 Section 2 - section 4 à p. 5 - 114
3 Section 3 - section 4 à p. 5 - 112
4 Section 3 - section 3 à p. 5 - 114
5 Section 2 - section 3 à p. 5 - 116
6 Section 1 - section 2 à p. 5 - 118
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Swing-away lattice
5.4 Rigging work
Section 2 -
section 3
Making 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.
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Swing-away lattice
5.4 Rigging work
5.4.24 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 Operating manual GMK5250L.
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 jumpered; à Operating manual GMK5250L.
On section 1
• Plug the lifting limit switch (4) onto the
holder (3).
• Secure the lifting limit switch.
• Secure 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 Operating
manual GMK 5250L.
On section 2
• Plug the lifting limit switch (4) onto the
holder (3).
• Secure the lifting limit switch.
• Secure 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 Operating
manual GMK 5250L.
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Swing-away lattice
5.4 Rigging work
5.4.29 Set the swing-away lattice down on the rear connection
When you unrig the swing-away lattice 2.0 + 19.3 m or install it in the
transport position then you must set it down on the console at the rear
connection.
S
Risk 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 swing-away lattice.
Do not lower the swing-away lattice below the position shown by the
markings.
This prevents damage to the connecting points or add-on parts.
• Lower the swing-away lattice until the
3 markings (1) and (2) line up.
The swing-away lattice is lowered onto the
supports (3) at the rear connection.
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Swing-away lattice
5.6 Maintenance
5.6.3 Maintenance plan M 3 M3
Maintenance work on the LATTICE EXTENSION:
every three months/after 250 oper. hrs.
Swing-away lattice
– Check the sheaves à p. 5 - 146
5.6.4 Maintenance plan M 12 M 12
Maintenance work on the LATTICE EXTENSION:
every 12 months/after 1,000 oper. hrs.
Swing-away lattice
– Lubricate joints à p. 5 - 151
5.6.5 Description of maintenance work
Pin
Grease 1) Designation Specification GROVE
to DIN 51502 Classification section no.1)
Grease KP - L2K DIN 51825 00554201
1)
à Maintenance Manual
Prerequisite
– The truck crane must be secured against unauthorised use; à Maintenance Ma
.
or
– The swing-away lattice is removed; à p. 5 - 33.
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Swing-away lattice
5.7 Troubleshooting
Extend swivel ram
• Select the symbol (4).