9

4
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Operating instructions for lattice extension

Serial number: 2 084 770 en

08.05.2003
 Important note

Duplications of any kind and excerpts from this

document are not subject to the revision service.
Original documents of Deutsche GROVE GmbH
are marked with the blue serial number of the
truck crane on the cover page.

Duplications and print-outs of data carriers on

which Deutsche GROVE GmbH has delivered this
document are also not subject to the revision
service.

4 9
93
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51

©
Copyright reserved by Deutsche GROVE GmbH
08.05.2003

The passing on or duplication of this document as well as the utilization and disclosure of its contents are prohibited
unless expressly permitted. Infringement will incur liability to compensation. All rights pertaining to registration of patent
or utility model are reserved.
 The following chapters are contained in these operating
instructions:

1 Important information

2 Transport dimensions and weights

3 Two-stage swing-away lattice extension

4 Boom extension

5 Auxiliary single-sheave boom top

6 Heavy load lattice extension

Alphabetical index

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51
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 51
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49

08.05.2003
 Table of content

1 Important information . . . . . . . . . . . . . . . . . . . 1-1

1.1 About these operating instructions . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

1.2 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2.1 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2

1.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

1.4 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

1.5 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7

1.6 Safety instructions for truck crane work . . . . . . . . . . . . . . . . . . . . . 1 - 8

1.7 The units of measurement in US units . . . . . . . . . . . . . . . . . . . . . . 1 - 10

4 9
93
2 Transport dimensions and weights . . . . . . . . . . . . 2-1

2.1 In metric units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

00

2.1.1 Two-stage swing-away lattice extension and boom extension . . . . . . . 2-1

2.1.2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
51

2.2 In US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
2.2.1 Two-stage swing-away lattice extension and boom extension . . . . . . . 2-2
2.2.2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

3 Two-stage swing-away lattice extension

(additional equipment) . . . . . . . . . . . . . . . . . . . 3-1

3.1 Identification of the two-stage swing-away lattice extension . . . . . . . . . 3 - 1

3.2 Assembly of lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3

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Operating instructions for lattice extension 2 084 770 en i-1

GMK 5100
3.3 Centre of gravity positions for slinging . . . . . . . . . . . . . . . . . . . . . 3 - 4

3.4 Check lists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

3.4.1 Overview of the required rigging work . . . . . . . . . . . . . . . . . . . . 3-5
3.4.2 CHECKLIST: Installing two-stage swing-away lattice extension . . . . . . . 3 - 6
3.4.3 CHECKLIST: Removing (two-stage) swing-away lattice extension . . . . . . 3 - 7
3.4.4 CHECKLIST: Rigging the 11 m swing-away lattice extension . . . . . . . . 3-9
3.4.5 CHECKLIST: Unrigging the 11 m swing-away lattice extension . . . . . . . 3 - 13
3.4.6 CHECKLIST: Rigging the 18 m two-stage swing-away lattice extension . . . 3 - 17
3.4.7 CHECKLIST: Unrigging the 18 m two-stage swing-away lattice extension . 3 - 21

3.5 Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27

3.5.1 Preparing the truck crane for rigging . . . . . . . . . . . . . . . . . . . . . 3 - 27
3.5.2 Checking the transport condition . . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
3.5.3 Folding the run-up rail out/in . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32
3.5.4 Connections with folded lattice extension . . . . . . . . . . . . . . . . . . . 3 - 33
3.5.5 Pin connections on the main boom head . . . . . . . . . . . . . . . . . . . 3 - 39

9
3.5.6 Pin connections on the lattice extension . . . . . . . . . . . . . . . . . . . . 3 - 42
3.5.7 4
Swivelling lattice extension onto the main boom head . . . . . . . . . . . 3 - 45
93
3.5.8 Swivelling the lattice extension when rigging . . . . . . . . . . . . . . . . . 3 - 46
3.5.9 Adjusting angle on the lattice extension . . . . . . . . . . . . . . . . . . . . 3 - 48
3.5.10 Folding deflection sheave on 11 m section out/in . . . . . . . . . . . . . . . 3 - 51
00

3.5.11 Positioning/removing the hoist cable . . . . . . . . . . . . . . . . . . . . . 3 - 52

3.5.12 Electrical connection on the lattice extension . . . . . . . . . . . . . . . . 3 - 55
51

3.5.13 Lifting limit switch on the lattice extension . . . . . . . . . . . . . . . . . . 3 - 58

3.5.14 Anemometer on the lattice extension . . . . . . . . . . . . . . . . . . . . . 3 - 60
3.5.15 Transportation on a separate vehicle . . . . . . . . . . . . . . . . . . . . . 3 - 61

3.6 Raising and setting down the main boom with rigged lattice extension . . . 3 - 63

3.7 Telescoping with rigged lattice extension . . . . . . . . . . . . . . . . . . . . 3 - 65

3.8 Operation with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . 3 - 67

3.8.1 SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 67
3.8.2 Procedure if the permissible wind speed is exceeded . . . . . . . . . . . . 3 - 68

3.9 Turning loads with the lattice extension . . . . . . . . . . . . . . . . . . . . . 3 - 69

3.9.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 69
3.9.2 Setting SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 70

3.10 Driving with rigged crane and lattice extension installed . . . . . . . . . . . 3 - 73

3.10.1 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 73
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3.10.2 Position of the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 74

i-2 2 084 770 en Operating instructions for lattice extension

GMK 5100
 3.10.3 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77

3.11 Malfunction when working with lattice extension! . . . . . . . . . . . . . . . 3 - 80

3.12 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 81

3.12.1 Modules requiring protection during cleaning work . . . . . . . . . . . . . 3 - 81
3.12.2 Maintenance work M1, monthly . . . . . . . . . . . . . . . . . . . . . . . . 3 - 82

4 Boom extension (additional equipment) . . . . . . . . . 4-1

4.1 Identification and slinging points . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
4.1.2 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Assembly of boom extensions . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3

4.3 Check lists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5

9
4.3.1 CHECKLIST: Installing the 26 m/34 m boom extension . . . . . . . . . . . . 4 - 5
4.3.2 4
CHECKLIST: Removing the 26 m/34 m boom extension . . . . . . . . . . . 4 - 8
93
4.4 Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
4.4.1 Installing/disassembling 8 m sections . . . . . . . . . . . . . . . . . . . . . 4 - 11
00

4.4.2 Installing/removing two-stage swing-away lattice extension for boom

extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
4.4.3 Electrical connection on the boom extension . . . . . . . . . . . . . . . . . 4 - 13
51

4.4.4 Folding out/in the deflection sheaves on the 8 m sections . . . . . . . . . . 4 - 15

4.4.5 Positioning/removing the hoist cable . . . . . . . . . . . . . . . . . . . . . 4 - 16

4.5 Driving with a rigged crane if boom extension is rigged . . . . . . . . . . . . 4 - 19

4.5.1 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
4.5.2 Position of the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
4.5.3 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22

4.6 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25

4.6.1 Maintenance work M1, monthly . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25

5 Auxiliary single-sheave boom top (additional equipment) 5-1

5.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Installing/removing auxiliary single-sheave boom top . . . . . . . . . . . . 5-3

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Operating instructions for lattice extension 2 084 770 en i-3

GMK 5100
5.2.2 Removing the auxiliary single-sheave boom top . . . . . . . . . . . . . . . 5 - 4

5.3 Rigging the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . 5-5

5.3.1 Rigging in transport position . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.2 Rigging in working position . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.3 Attaching and removing hoist cable . . . . . . . . . . . . . . . . . . . . . . 5 - 7
5.3.4 Possible reeving methods on the auxiliary single-sheave boom top . . . . 5 - 7
5.3.5 Lifting limit switch and anemometer . . . . . . . . . . . . . . . . . . . . . 5-8

5.4 Turning loads with the auxiliary single-sheave boom top . . . . . . . . . . . 5 - 9

6 Heavy load lattice extension . . . . . . . . . . . . . . . 6-1

6.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

6.2 Mount / remove heavy load lattice extension . . . . . . . . . . . . . . . . . . 6 - 3

6.2.1 Installing the heavy load lattice extension . . . . . . . . . . . . . . . . . . 6-3

9
6.2.2 Removing the heavy load lattice extension . . . . . . . . . . . . . . . . . 6-4

6.3 Rigging work check lists

4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
93
6.3.1 CHECK LIST: Changing the heavy load lattice extension . . . . . . . . . . 6-5
6.3.2 CHECK LIST: Unrigging heavy load lattice extension . . . . . . . . . . . . 6-7
00

6.4 Rigging / unrigging the heavy load lattice extension . . . . . . . . . . . . . 6-9

6.4.1 Rigging the heavy load lattice extension . . . . . . . . . . . . . . . . . . . 6-9
51

6.4.2 Removing the heavy load lattice extension . . . . . . . . . . . . . . . . . . 6 - 19

6.5 Operation with the heavy load lattice extension . . . . . . . . . . . . . . . . 6 - 21

6.5.1 Telescoping with rigged heavy load lattice extension . . . . . . . . . . . . 6 - 22
6.5.2 Raising and placing the main boom with rigged heavy load lattice
extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22

6.6 Turning loads with the heavy load lattice extension . . . . . . . . . . . . . . 6 - 23

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i-4 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Important information
1.1 About these operating instructions

1 Important information

H
1.1 About these operating instructions

All the lattice extensions described in these operating instructions can be

obtained as additional equipment.

Validity of this This operating manual only applies to lattice extensions which were deli-
operating manual vered by Deutsche GROVE GmbH.

In addition, for the operation of the truck crane with a lattice extension
described in these operating instructions, all details in the included Opera-

9
ting Instructions for the GMK 5100 (for which the lattice extension was deli-
vered from the factory) are applicable.
4
93

Prerequisites for The lattice extensions described in these operating instructions may only
00

assembly and be operated together with a GROVE GMK 5100 truck crane whose serial
operation number is identical with the serial number that is marked on the lattice ex-
tensions.
51

Safety The operation of the GMK 5100 with one of the lattice extensions descri-
instructions bed in these operating instructions is subject to

– all the basic safety instructions to be found in the subsequent section

Basic safety instructions and
– all the safety instructions contained in the supplied operating instructi-
ons for the GMK 5100.

Reference to Cross references to other operating or maintenance instructions are sta-

other operating ted as follows:
instructions ➠ GMK 5100 Operating Instructions, part 2 Superstructure – Rigging work
You will find the number of the chapter bearing the name Rigging work at
08.05.2003

the front, on the second page of the stated operating instructions.

s
Operating instructions for lattice extension 2 084 770 en 1-1
GMK 5100
Important information
1.2 Basic safety instructions

1.2 Basic safety instructions

1.2.1 Warnings and symbols

The following definitions and symbols are used in the operating instructi-
ons to highlight particularly important information:

G
This symbol indicates hazards related to the described operation that
may cause personal injury. The type of danger (e.g. danger of life, perso-
nal injury or risk of crushing) is as a rule specified in the warning sign.

S
Here dangers are referred to which could put objects at risk, e.g. damage
to the truck crane, the load or the environment.

4 9
B
This symbol alerts you to situations where you are in danger of receiving
93
an electric shock.
00

O
This symbol is to remind you that you are working with substances which
pose a risk to the environment. Take particular care. Further information
51

about handling substances which are harmful to the environment;

➠ Maintenance manual, Chapter Safety and environmental protection.

The vertical line to the left of the text indicates: this text regardless of its
length belongs to the warning symbol.

H The hand with the pointing finger indicates passages that contain additio-
nal instructions and tips with regard to truck crane operation.

s This symbol indicates that the topic is continued on the next page. So
turn to the next page!
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1-2 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Important information
1.3 Proper use

1.3 Proper use

The truck crane GMK 5100 was constructed in accordance with state of
the art technology and the recognized safety regulations. Nevertheless,
personal injury to the operator or a third party as well as damage to the
crane and other property may occur during use.

The truck crane may only be modified with the consent of the manufacturer.

The GMK 5100 truck crane must be in proper working condition and may
only be used for its intended purpose, while taking into account safe ope-
ration and any possible hazards.
Malfunctions that may affect the safe operation of the unit are to be
corrected immediately.

The GMK 5100 truck crane may only be operated at temperatures of be-
tween –25 and +40 °C if it is not equipped with the relevant special equip-
ment.

9
The GMK 5100 truck crane is to be used exclusivly for vertical lifting of
loads whose weight and centre of distribution are known. A hook block
4
must be reeved on the hoist rope and such lifting must be done only in
93
the permitted rigging modes. Any other use of the crane is considered im-
proper. The manufacturer is not liable for damage resulting from impro-
per or unauthorized use of the GMK 5100 truck crane. The user shall take
00

on full responsibility for any such use.

51

Proper use also entails

– observing all crane documentation consisting of the operating instruc-
tions, the lifting capacity table, the outrigger pressure table and the
safety manual,
– following the inspection and maintenance requirements specified in the
Maintenance manual.
08.05.2003

s
Operating instructions for lattice extension 2 084 770 en 1-3
GMK 5100
Important information
1.3 Proper use

Improper use includes:

– transporting loads on the carrier,
– pushing, pulling or lifting loads with the level adjustment system, the
beams or the outrigger cylinders,
– pushing, pulling or lifting loads off the ground using the slewing gear,
the derricking gear or the telescoping gear,
– pulling off fixed objects using the crane,
– two-hook operation with the boom extension and two-hook operation
on the main boom head without additional equipment,
– operation when crane is not on outriggers (free on wheels),
– defining SLI codes that do not correspond to the actual rigging mode,
– working with an overridden SLI or overridden lifting limit switch,
– after SLI deactivation, the radius must be increased by pulling the rai-
sed load at an angle (e.g. with a chain hoist).

9
– Misuse of the outrigger pressure display as a safety function to prevent
overturning after an SLI shutdown (outrigger pressure greater than 0 t),
4
– road driving in an unauthorized driving mode (axle load, dimension),
93
– moving the rigged crane in an unauthorized driving mode,
– the transportation of raised loads by moving the truck crane,
00

– use of equipment that is not authorized for use with the crane,
– transporting passengers on unauthorized parts of the vehicle,
51

– transporting passengers without previous written permission from the

manufacturer,
– carrying passengers outside the driver’s cab,
– loading and unloading work, i.e. continuous operation without a corre-
sponding break,
– usage for any kind of sport or recreation event, especially for “Bungee“
jumping.
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1-4 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Important information
1.4 Organizational measures

1.4 Organizational measures

The operating instructions and the lifting capacity table should be kept in
the truck crane for immediate access at all times and must not be remo-
ved from the truck crane. You need to have read and understood the ope-
ration and safety instructions in these operating instructions and to com-
ply with them when working.
In addition to the operating instructions and the lifting capacity table,
observe all general, statutory and otherwise applicable regulations con-
cerning accident prevention and environmental protection. You must
have read and understood these and work accordingly.
This could include:
– the use of hazardous materials,
– wearing personal protective equipment,
– traffic regulations or
– all applicable regulations concerning the operation of a crane.

9
Ensure that those appointed to work on the truck crane are given the infor-
4
mation required to carry out the work before starting operations. Give
your employees (e.g. banksmen, slingers, rigging personnel) appropriate
93
instruction.

Ensure that the maintenance personnel possess the necessary know-how

00

to safely operate the crane. Ensure that the maintenance personnel have
access to the operating instructions.
51

Only properly trained or instructed personnel may carry out work on the
truck crane.
Responsibilities related to crane operation, rigging, maintenance and re-
pair work must be clearly defined.

Ensure that only the appointed employees operate the truck crane.

Do not leave long hair down or wear loose clothing or jewellery (including
rings) when working with the crane. These could get caught or pulled into
the unit and result in injury.

Use your personal protective equipment whenever necessary or prescribed.

Observe all safety and warning signs on the truck crane.

Ensure that all safety and warning signs on the truck crane remain legible.
08.05.2003

s
Operating instructions for lattice extension 2 084 770 en 1-5
GMK 5100
Important information
1.4 Organizational measures

Note the operational organization on the site. Report your arrival to site
management. Ask for the personnel authorized to issue instructions.

Familiarize yourself with the location and operation of the fire extinguis-
hers on every site.

Note the fire alarm and fire fighting facilities on the site.

Should the operating behaviour of the truck crane change in such a man-
ner that safety is affected or if you doubt the truck craneïs operating safe-
ty, stop the machine immediately and inform the appropriate responsible
persons.

Do not modify any programs in programmable control systems (e.g. the SLI).

Do not modify or mount attachments to the truck crane without the con-
sent of the manufacturer, if such changes could affect the safety of the
unit. This also applies to
– installing safety devices,

9
– setting safety devices and valves.
4
Welding work on load-bearing parts may only be conducted by properly
93
qualified personnel following authorisation by the manufacturer. To avoid
any damage, especially to electronic parts, there are certain steps you
must take before doing any welding work. So always consult GROVE
00

Product Support before doing any welding work.

Ensure that both the prescribed periods and the periods specified in the
51

operating and maintenance instructions for regular testing, inspection

and maintenance work are maintained.

Replace the hydraulic hose lines at the prescribed intervals or have them
replaced, even if no safety defects are noticeable.

Replacement parts must fulfill the technical requirements prescribed by

the manufacturer. Genuine spare parts always meet these requirements.

It is imperative that appropriate service equipment be used when carrying

out repair work.
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1-6 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Important information
1.5 Personnel qualifications

1.5 Personnel qualifications

These operating instructions are not a training manual for prospective cra-
ne operators!
All descriptions are written explicitly for crane operators who have been
trained to operate truck cranes.

Employees in training may only operate the truck crane under strict super-
vision.

Only reliable personnel may operate the truck crane.

As a truck crane operator you are obliged to fulfill a number of require-

ments:
– You must possess a driving licence for this type of vehicle that is valid
in the country in which you are working.
– You must have general knowledge of crane operation and any qualifica-
tions that may be required by the country in which you are working.

9
– You must be familiar with and have understood the operating instruc-
tions. 4
93
– You must be familiar with and have understood the accident prevention
regulations.
– You must be in proper physical and psychological condition for opera-
00

ting the truck crane, e.g. perfect sight and vision or good reactive ability.
Please refer to the section titled You as crane driver and operator in the Safety
51

Manual.

Only experienced personnel familiar with the applicable accident preventi-

on regulations are authorized to sling loads and train crane operators.

Your responsibilities as a crane operator (including those concerning traf-

fic regulations) must be clearly defined. You must be in a position to refu-
se to carry out any instructions given to you by a third party that violate
safety regulations.

Only trained, experienced personnel with special knowledge in the fields

of hydraulics, pneumatics and electrical equipment may carry out main-
tenance work on the truck crane.

The Deutsche GROVE GmbH gives general and type-related crane opera-
tor and technical courses.
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Operating instructions for lattice extension 2 084 770 en 1-7

GMK 5100
Important information
1.6 Safety instructions for truck crane work

1.6 Safety instructions for truck crane work

Carefully select a safe site for the truck crane to stand from where you can
safely work.

Walk around the truck crane before beginning crane work. Check the con-
dition of the truck crane carefully using the check lists in the operating in-
structions. Do not assume that everything is in working order simply
because it was in working order when work was last completed.

Each day, before you start to work with the crane, check that all covers
and safety devices are correctly fitted and that they are all in a proper
working condition.

Check the safety devices each day before beginning work (SLI, lifting limit
switch, dead man’s switch, emergency stop switch for crane control).

Use the appropriate access aids when carrying out overhead rigging or
maintenance work. Do not use parts of the crane as access aids.

9
Walk only on those machine parts which are equipped with appropriate
4
steps and railings and therefore guarantee safety. During rigging and
93
maintenance work on machine sections above body height which have no
apparatus for walking, use the extendable ladder which accompanies the
machine (e. g. when reeving the hoist cable on the boom nose).
00

Keep all handles, steps, step treads and ladders free of dirt, snow and ice.
51

Check all operating and control elements in the crane operator’s cab
before starting the crane engine.

Monitor all warning and indicator lamps as well as the control instru-
ments when the engine is started!

Make sure that there are no unauthorised people in the vicinity of or on

the truck crane when rigging or during crane work. Secure the danger
zone using cordons and mark them as such.

When lifting a load, raise the boom to balance out the increase in radius
caused by the boom bending so that the load is lifted up when in a verti-
cal position and does not drag, injure helpers or fall into the hoist cable
diagonally (e.g. from a vehicle or scaffold). Inform banksmen and helpers
about this as well.
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1-8 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Important information
1.6 Safety instructions for truck crane work

Support the truck crane with the supporting span for the current rigged
counterweight before turning the superstructure.

Ensure that the truck crane is horizontally aligned before carrying out
crane work.

Only use equipment (counterweight sections, lattice extensions) that be-

longs to your truck crane. The serial number of both the truck crane and
the equipment must be identical.

Simultaneously lifting loads with two cranes is particularly dangerous.

Use extreme caution when carrying out this type of work.

When work is interrupted, always put the load down and never leave the
truck crane if a load is raised.

Lock the truck crane when you leave the cab to prevent unauthorised use.

Crane work carried out in the vicinity of electric cables as well as oil, gas

9
and other supply lines is dangerous and requires that special precau-
tionary measures be taken. Please refer to the section titled Crane operation
4
under special operating conditions in the Safety Manual and observe the rele-
93
vant national regulations.

Always check if all other required connections are established, before you
00

loosen a connection between the lattice extension and main boom or a

connection between the lattice extension sections during rigging or unrig-
ging work. Never loosen all the connections.
51
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Operating instructions for lattice extension 2 084 770 en 1-9

GMK 5100
Important information
1.7 The units of measurement in US units

1.7 The units of measurement in US units

These operating instructions use mainly metric units of measurement.
Should you be working in a country that uses US units of measurement,
refer to the following table for a comparison of the units.

– the first column shows the units of measurement as used in these in-
structions;
– the second column shows the converted units of measurement, which
are also used in the lifting capacity tables;
– the third column shows the rounded values which are used for better
legibility if both units of measurement are stated (in Chapter 2, Trans-
port dimensions and weights and in the diagrams showing the compo-
sition of the individual lattice extensions.

Stated length in Corresponding length in Rounded length in

metric units of measurement US units of measurement US units of measurement

9
acc. to lifting capacity table in these operating instructions

11 m 36.1 ft 4 36 ft
93
Lattice extension
18 m 59.1 ft 59 ft
Two-stage swing-away lattice
00

extension
26 m 85.3 ft 85 ft
Boom extension
51

34 m 111.6 ft 112 ft
Boom extension
7 m section 23.0 ft 23 ft

8 m section 26.2 ft 26 ft

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1 - 10 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Transport dimensions and weights
2.1 In metric units

2 Transport dimensions and weights

2.1 In metric units

This section contains the transport dimensions and weights of the lattice
extensions in metric units.

2.1.1 Two-stage swing-away lattice extension and boom extension

4 9
Description Length x width x Weight (kg)
height (m)
93
Two-stage swing-away lattice 11.50 x 1.00 x 1.50 1 400
extension (complete folded)
00

11 m section 11.50 x 1.00 x 1.50 1 000

7 m section 7.20 x 0.60 x 0.70 400

51

8 m section with deflection 8.20 x 0.90 x 1.30 700

sheave

8 m section without deflection 8.20 x 0.90 x 1.30 650

sheave

2.1.2 Auxiliary single-sheave boom top

Description Length x width x Weight (kg)

height (m)

Auxiliary single-sheave boom 1.00 x 0.40 x 1.00 60

top with pin
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Operating instructions for lattice extension 2 084 770 en 2-1

GMK 5100
Transport dimensions and weights
2.2 In US units

2.2 In US units
This section contains the transport dimensions and weights of the lattice
extensions in US units.

2.2.1 Two-stage swing-away lattice extension and boom extension

Description Length x width x Weight (lbs)

height (ft)

Two-stage swing-away lattice 37.73 x 3.28 x 4.92 3 087

extension (complete folded)

11 m section 37.73 x 3.28 x 4.92 2 205

7 m section 23.62 x 1.97 x 2.30 882

8 m section with deflection 26.90 x 2.95 x 4.27 1 543

9
sheave

8 m section without deflec- 426.90 x 2.95 x 4.27 1 433

93
tion sheave
00

2.2.2 Auxiliary single-sheave boom top

51

Description Length x width x Weight (lbs)

height (ft)

Auxiliary single-sheave boom 3.28 x 1.31 x 3.28 133

top with pin 08.05.2003

2-2 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.1 Identification of the two-stage swing-away lattice extension

3 Two-stage swing-away lattice extension

(additional equipment)

3.1 Identification of the two-stage swing-away lattice

extension
The two-stage swing-away lattice extension is designed for the truck
crane it was delivered with. The two-stage swing-away lattice extension
sections belonging to the truck crane have the same serial number as the
truck crane.

The following sections are identified by the serial number:

– the 11 m section on the fixed section,

9
– the 11 m section on the inclinable section,
– the 7 m section.
4
93

S
Only operate two-stage swing-away lattice extension sections which have
the same serial number as the crane.
00

The SLI is only set for this two-stage swing-away lattice extension.

H
This prevents malfunctions and damage.
51

For technical reasons a truck crane may only be set with one two-stage
swing-away lattice extension.

If you wish to use the two-stage swing-away lattice extension on several

GROVE Truck Cranes, the two-stage swing-away lattice extension sections
must be adjusted for the corresponding cranes and labelled with all of the
respective serial numbers.

S
The two-stage swing-away lattice extension should only be adjusted by
your local GROVE Product Support!
08.05.2003

s
Operating instructions for lattice extension 2 084 770 en 3-1
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.1 Identification of the two-stage swing-away lattice extension

Serial numbers The 11 m section consists of a fixed section and an inclinable section.
on 11 m section

On the inclinable section the serial number

(1) is at the front on a sheet to the right of
the deflection sheave.

On the fixed section the serial number (2) is

at the rear on a sheet in the upper boom.

4 9
93
00

Serial number on
7 m section
51

On the 7 m section the serial number (1) is at

the rear on the left-hand side plate.

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3-2 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.2 Assembly of lattice extensions

3.2 Assembly of lattice extensions

11 m swing-away lattice extension

(36 ft swing-away lattice extension)

11 m section
(36 ft section)

4 9
93
18 m swing-away lattice extension
(59 ft swing-away lattice extension)
00

11 m section 7 m section
51

(36 ft section) (23 ft section)

H The lengths of 11 m and 18 m respectively equal the distance between the

centre of the locking pin (on the main boom head) and the front edge of
the head sheave.
The designations 11 m section and 7 m section have been adapted to
these lengths. The total lengths of the individual sections are greater;
➠ Transport dimensions and weights, p. 2-1.
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Operating instructions for lattice extension 2 084 770 en 3-3

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.3 Centre of gravity positions for slinging

3.3 Centre of gravity positions for slinging

Observe the centres of gravity of the lattice extension and the swing-away
lattice extension when you sling the lattice extension to an auxiliary crane
for removal or installation.

G
Risk of accidents from falling two-stage swing-away lattice extension!
Always observe relevant centres of gravity shown in illustration below
when slinging and use suitable slinging material with sufficient lifting ca-
pacity; ➠ Transport dimensions and weights, p. 2-1.
In this way you prevent the lattice extension from slipping or falling
during installation or deinstallation and injuring people.

4 9
93
00
51

The distances are always measured from the centre of the fork elements.

For the 18 m two-stage swing-away lattice extension, swung out, the

distance for the centre of gravity (1) = 7 230 mm ((284,7 inch).

For the 18 m two-stage swing-away lattice extension, folded, the distance

for the centre of gravity (2) = 5 580 mm (219,7 inch).

For the 11 m two-stage swing-away lattice extension on its own, the

distance for the centre of gravity (3) = 4 700 mm (185,0 inch).

For the 7 m two-stage swing-away lattice extension on its own, the dis-
08.05.2003

tance for the centre of gravity (4) = 3 200 mm (126,0 inch).

3-4 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

3.4 Check lists for rigging work

3.4.1 Overview of the required rigging work

There are different initial states for rigging the lattice extension, depen-
ding on whether

– the lattice extension is folded at the side of the main boom or

– the lattice extension has been dismantled for on-road driving, Driving
mode tables ➠ GMK 5100 Operating Instructions, part 1 Carrier – Driving
the truck crane.

The following table shows you which checklist describes the required rig-
ging work for your initial state.

9
Initial state Corresponding rigging work
4
93
CHECKLISTS:
Rigging the 11 m swing-away
Lattice extension is on the lattice extension; ➠ p.3-9.
side of the main boom Rigging the 18 m two-stage
00

Before swing-away lattice extension;

crane ➠ p. 3-17.
operation
51

CHECKLIST:
Lattice extension was Installing the (two-stage)
removed completely swing-away lattice extension;
➠ p. 3-6.
CHECKLISTS:
Unrigging the 11 m swing-
Lattice extension should be away lattice extension;
folded at the side of the ➠ p. 3-13.
After main boom Unrigging the 18 m two-stage
crane
swing-away lattice extension;
operation ➠ p. 3-21.
CHECKLIST:
Lattice extension is to be Removing the (two-stage)
removed for on-road driving swing-away lattice extension;
➠ p. 3-7.
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Operating instructions for lattice extension 2 084 770 en 3-5

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

3.4.2 CHECKLIST: Installing two-stage swing-away lattice extension

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Requirements
– The truck crane is on outriggers or the main boom is placed on the
boom support.
– An auxiliary crane must be ready.

1. Check the transport condition of the (two-stage) swing-away lattice

extension;
➠ Checking transport condition with removed lattice extension, p. 3-31.

4 9
93
2. Slinging (two-stage) swing-away lattice extension on auxiliary crane;
➠ Centre of gravity positions for slinging, p. 3-4.
00
51

3. Lift (two-stage) swing-away lattice extension in front of the main

boom with auxiliary crane and lock 11 m section onto the right of the
main boom head; ➠ Pin connections on the main boom head, p. 3-39.

4. Secure a guide rope to the head of the 11 m section.

H
08.05.2003

If the lattice extension needs to be rigged in front of the main boom, see
point 7.

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 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

5. If the lattice extension is to be folded up at the side of the main boom,

fold out run-up rail; ➠ Folding the run-up rail in/out, p. 3-32.

6. The other types of rigging work for folding up the lattice extension at
the side are described in the CHECKLIST: Unrigging 11 m swing-away lat-
tice extension from point 12 onwards, p. 3-14.

7. If the lattice extension is to be rigged in front of the main boom, at-

tach guide rope to the head of the 11 m section.
The other types of rigging work for the 11 m swing-away lattice exten-

9
sion are described in the CHECKLIST: Rigging the 11 m swing-away latti-
ce extension from point 12 onwards, p. 3-11.
4
The other types of rigging work for the 18 m two-stage swing-away
93
lattice extension are described in the CHECKLIST: Rigging the 18 m two-
stage swing-away lattice extension from point 9 onwards, p. 3-18.
00
51

3.4.3 CHECKLIST: Removing (two-stage) swing-away lattice

extension

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Requirements
– The truck crane is on outriggers or the main boom is placed on the
boom support.
– An auxiliary crane must be ready.
1. Carry out all of the rigging work for a rigged 11 m swing-away lattice
extension listed in the CHECKLIST: Unrigging 11 m swing-away lattice
extension up to and inclusive of point 11; ➠ p. 3-14.
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Operating instructions for lattice extension 2 084 770 en 3-7
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

2. Carry out all of the rigging work for a rigged 18 m two-stage swing-
away lattice extension listed in the CHECKLIST: Removing 18 m two-
stage swing-away lattice extension up until and inclusive of point 13,
➠ p. 3-23.

3. Sling (two-stage) swing-away lattice extension on auxiliary crane;

➠ Centre of gravity positions for slinging, p. 3-4.

4. Remove locking pins on both sides between 11 m section and main

boom head and place (two-stage) swing-away lattice extension onto
separate vehicle using auxiliary crane; ➠ Pin connections on the main
boom head, p. 3-39; ➠ Transportation on separate vehicle, p. 3-61.

4 9
93
5. Check the transport condition of the (two-stage) swing-away lattice
00

extension;
➠ Checking transport condition with removed lattice extension, p. 3-31.
51

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 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

3.4.4 CHECKLIST: Rigging the 11 m swing-away lattice extension

H This checklist is not a complete operating manual. There are accompany-

ing instructions, which are indicated by cross-references. Observe the
warning and safety information given there!

1. Prepare the truck crane for rigging the swing-away lattice extension;
➠ Preparing the truck crane for rigging, p. 3-27.
2. Check that the lattice extension was unrigged properly and is in trans-
port condition; ➠ Checking transport condition with lattice extension folded
at the side, p. 3-31.

3. Fold out the run-up rail; ➠ Folding the run-up rail in/out, p. 3-32.

4 9
93

H
00

If only the 11 m section is folded at the side of the main boom – proceed
51

as from point 7.

4. Connect 7 m section to run-up rail; ➠ Connections on the run-up rail,

p. 3-36.

5. Release connection between 7 m section and 11 m section;

➠ Connections in the middle area, p. 3-35.
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Operating instructions for lattice extension 2 084 770 en 3-9
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

6. Release connection at the pivot point between 11 m section and 7 m

section; ➠ Pin connections on the lattice extension, p. 3-42.

7. If only the 11 m sectionis folded at the side of the main boom, remove
connection between 11 m section and main boom (rear);
➠ Connections in the rear area, p. 3-38.

8. Swing 11 m section onto the main boom head; ➠ Swinging the lattice
extension onto the main boom head, p. 3-45.

4 9
93
9. Lock 11 m section onto the main boom head; ➠ Pin connections on the
00

main boom head, p. 3-39.

51

10. Secure lattice extension on main boom with guide rope;

➠ Securing lattice extension with cord, p. 3-28.

11. Unlock and remove connection between 11 m section and main boom
(front); ➠ Connections in the front area, p. 3-33.
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GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

12. Swing 11 m section in front of the main boom; ➠ Swivelling the lattice
extension during rigging, p. 3-46.

13. Pin 11 m section onto main boom head, on left-hand side;

➠ Pin connections on the main boom head, p. 3-39.

14. Establish electrical connection between lattice extension and main

boom; ➠ Electrical connection on the lattice extension, p. 3-55.

4 9
93
15. Fold out deflection sheave on 11 m section. ➠ Folding deflection sheave
00

on 11 m section in/out, p. 3-51.

51

16. Adjust angle if necessary; ➠ Adjusting angle on the lattice extension,

p. 3-48.

17. Place hoist cable over both deflection sheaves and head sheave of the
11 m section; ➠ Positioning/removing the hoist cable, p. 3-52.
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s
Operating instructions for lattice extension 2 084 770 en 3 - 11
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

18. Move anemometer from the head of the main boom to the head of
the 11 m section; ➠ Anemometer on lattice extension, p. 3-60.

19. Move lifting limit switch from the head of the main boom to the head
of the 11 m section; ➠ Lifting limit switch on the lattice extension, p. 3-58.

20. Reeve the hoist cable on the hook block; ➠ Possible reeving methods on
the lattice extension, p. 3-54.

4 9
93
21. Attach lifting limit switch weight and guide hoist cable through the
weight; ➠ GMK 5100 Operating Instructions, part 2 Superstructure –
00

Rigging work.
51

22. Enter the SLI code according to theLifting capacity table for the actual
00== rigging mode of the truck crane with the 11 m lattice extension, Setting
the rigging mode, ➠ GMK 5100 Operating Instructions, part 2 Superstruc-
ture – Crane operation.

Further working steps for raising the boom; ➠ p. 3-63.

Telescoping with rigged lattice extension; ➠ p. 3-65.
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3 - 12 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

3.4.5 CHECKLIST: Unrigging the 11 m swing-away lattice extension

H This checklist is not a complete operating manual. There are accompany-

ing instructions, which are indicated by cross-references. Observe the
warning and safety information given there!

1. Prepare the truck crane for unrigging; ➠ Preparing the truck crane for rig-
ging, p. 3-27.

2. Retract main boom completely and lower it into the horizontal positi-
on.

3. Enter the SLI code according to the Lifting capacity table for the actual

9
00== rigging mode of the truck crane with the 11 m lattice extension, Setting
the rigging mode, ➠ GMK 5100 Operating Instructions, part 2 Superstruc-
4
ture – Working with the crane.
93
4. Remove lifting limit switch weight and move lifting limit switch from
the head of the 11 m section to the head of the main boom; ➠ Lifting
00

limit switch on the lattice extension, p. 3-58.

51

5. Unreeve the hoist cable from the hook block and remove from the lat-
tice extension; ➠ Positioning/removing the hoist cable, p. 3-52.

6. Remove anemometer; ➠ Anemometer on the lattice extension, p. 3-60.

08.05.2003

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Operating instructions for lattice extension 2 084 770 en 3 - 13
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

7. Set angle at 0° if necessary; ➠ Adjusting angle on the lattice extension,

p. 3-48.

8. Fold in deflection sheave on 11 m section; ➠ Folding deflection sheave

on 11 m section in/out, p. 3-51.

9. Disconnecting an electrical connection between lattice extension and

main boom; ➠ Electrical connection on the lattice extension, – 11 m-two-sta-
ge swing-away lattice extension, p. 3-55.

4 9
93
10. Reel hoist cable up to the main boom head.
00
51

11. Secure guide rope to the head of the 11 m section.

12. Release left-hand connection between 11 m section and main boom

head; ➠ Pin connections on the main boom head, p. 3-39.
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3 - 14 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

13. Swivel the 11 m section towards the main boom until the connection
between the main boom (in the front area) and the 11 m section enga-
ges; ➠ Swivelling the lattice extension during rigging, p. 3-46.

14. Secure 11 m section to the main boom with locking pin;

➠ Connections in the front area, p. 3-33.

15. Remove right-hand locking pin between 11 m section and main boom;
➠ Pin connections on the main boom head, p. 3-39.

4 9
93

H If the 7 m section is not attached to the main boom – proceed as from

00

point 17.
51

16. Swivel the 11 m section on the run-up rail onto the main boom until
the connection between the 11 m section and the 7 m section enga-
ges; ➠ Connections in the middle area, p. 3-35.

17. Connect at the pivot point between 11 m section and 7 m section;

➠ Pin connections on the lattice extension, p. 3-42.

H If the 7 m section is attached to the main boom – proceed as from

point 19.
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Operating instructions for lattice extension 2 084 770 en 3 - 15
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

18. If the 7 m section is not available, swivel the 11 m section on the run-
up rail onto the main boom and lock it there; ➠ Connections in the rear
area, p. 3-38.

19. Check whether the lattice extension is in transport position;

➠ Checking transport condition, p. 3-29.

20. Fold in run-up rail; ➠ Folding the run-up rail in/out, p. 3-32.

4 9
93
00
51

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GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

3.4.6 CHECKLIST: Rigging the 18 m two-stage swing-away lattice

extension

H This checklist is not a complete operating manual. There are accompany-

ing instructions, which are indicated by cross-references. Observe the
warning and safety information given there!

1. Prepare the truck crane for rigging the swing-away lattice extension;
➠ Preparing the truck crane for rigging, p. 3-27.
2. Check that the lattice extension was unrigged properly and is in trans-
port condition; ➠ Checking transport condition with lattice extension folded
at the side, p. 3-31.

9
3. Fold out run-up rail; ➠ Folding the run-up rail in/out, p. 3-32.

4
93
00

4. Remove both connections between 7 m section and main boom;

51

➠ Connections in the rear area, p. 3-37.

➠ Connections on the run-up rail, p. 3-36.

5. Swivel lattice extension onto the main boom head; ➠ Swivelling the
lattice extension onto the main boom head, p. 3-45.

6. Fasten 11 m section to the main boom head with pin on right-hand

side; ➠ Pin connections on the main boom head, p. 3-39.
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Operating instructions for lattice extension 2 084 770 en 3 - 17
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

7. Secure lattice extension on main boom with guide rope; ➠ Securing

lattice extension with cord, p. 3-28.

8. Unlock and remove connection between 11 m section and main

boom; ➠ Connections in the front area, p. 3-33.

9. Swivel lattice extension in front of the main boom head; ➠ Swivelling

the lattice extension during rigging, p. 3-46.

4 9
93
10. Pin 11 m section to left side of main boom head; ➠ Pin connections on
00

main boom head, p. 3-39.

51

11. Establish electrical connection between lattice extension and main

boom; ➠ Electrical connection on the lattice extension, p. 3-55.

12. Attach guide rope to the head of the 7 m section.

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3 - 18 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

13. Release connection between 7 m section and 11 m section and swivel

7 m section in front of the 11 m section;
➠ Connections in the middle area, p. 3-35.
➠ Swivelling the 7 m section in front of the 11 m section, p. 3-47.

14. With locking pin, fasten 7 m section on left-hand side in front of 11 m

section; ➠ Pin connections on the lattice extension, p. 3-42.

15. Establish electrical connection between 11 m section and 7 m section;

➠ Electrical connection on the lattice extension – 18 m two-stage swing-away
lattice extension, p. 3-57.

4 9
93
16. Adjust angle if necessary; ➠ Adjusting angle on the lattice extension,
00

p. 3-48.
51

17. Fold out deflection sheave on 11 m section; ➠ Folding deflection sheaves

on 11 m section in/out, p. 3-51.

18. Place hoist cable over both deflection sheaves and head sheave of the
7 m section; ➠ Positioning/removing the hoist cable, p. 3-52.
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s
Operating instructions for lattice extension 2 084 770 en 3 - 19
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

19. Move anemometer from the head of the main boom to the head of
the 7 m section; ➠ Anemometer on lattice extension – 18 m two-stage
swing-away lattice extension, p. 3-60.

20. Move lifting limit switch from the head of the main boom to the head
of the 7 m section; ➠ Lifting limit switch on the lattice extension, p. 3-58.

21. Reeve the hoist cable on the hook block; ➠ Possible reeving methods on
the lattice extension, p. 3-54.

4 9
93
22. Attach lifting limit switch weight and guide hoist cable through the
weight; ➠ GMK 5100 Operating Instructions, part 2 Superstructure –
00

Rigging work.
51

23. Enter the SLI code according to theLifting capacity table for the actual
00== rigging mode of the truck crane with the 18 m lattice extension, Setting
the rigging mode; ➠ GMK 5100 Operating Instructions, part 2 Superstruc-
ture – Crane operation.

Further working steps for raising the boom; ➠ p. 3-63.

Telescoping with rigged lattice extension; ➠ p. 3-65.
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3 - 20 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

3.4.7 CHECKLIST: Unrigging the 18 m two-stage swing-away lattice

extension

H This checklist is not a complete operating manual. There are accompany-

ing instructions, which are indicated by cross-references. Observe the
warning and safety information given there!

1. Prepare the truck crane for unrigging; ➠ Preparing the truck crane for rig-
ging, p. 3-27.

2. Fully retract and set down main boom.

9
3. Enter the SLI code according to the Lifting capacity table for the actual
00== rigging mode of the truck crane with the 18 m two stage lattice exten-
4
sion, Setting the rigging mode ➠ GMK 5100 Operating Instructions, part 2
93
Superstructure – Crane operation.

4. Remove lifting limit switch weight and move lifting limit switch from
00

the head of the 7 m section to the head of the main boom; ➠ Lifting li-
mit switch on the lattice extension, p. 3-58.
51

5. Unreeve the hoist cable from the hook block and remove from the lat-
tice extension; ➠ Positioning/removing the hoist cable, p. 3-52.

6. Remove anemometer; ➠ Anemometer on the lattice extension, p. 3-60.

08.05.2003

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Operating instructions for lattice extension 2 084 770 en 3 - 21
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

7. Detach electrical connection between 7 m section and 11 m section;

➠ Electrical connection on the lattice extension – 18 m two-stage swing-away
lattice extension, p. 3-57.

8. Set angle at 0° if necessary; ➠ Adjusting angle on the lattice extension, p.

3-48.

9. Fold in deflection sheave on 11 m section;

➠ Folding deflection sheave on 11 m section in/out, p. 3-51.

4 9
93
10. Reel hoist cable up to the main boom head.
00
51

H If the 7 m section needs to be removed and only the 11 m section at the

side of the main boom needs to be folded, see point 14.

11. Attach guide rope to the head of the 7 m section.

12. Remove the locking pin on the left-hand side between 7 m section and
11 m section; ➠ Pin connections on the lattice extension, p. 3-42.
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3 - 22 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

13. Swivel the 7 m section to the side of the 11 m section until the connec-
tion between the 7 m section and the 11 m section engages;
➠ Swivelling the lattice extension during rigging, p. 3-47.
➠ Connections in the middle area, p. 3-35.

14. If the 7 m section needs to be removed, sling 7 m section on auxiliary

crane, remove all locking pins between 7 m section and 11 m section
and place 7 m section on separate vehicle.

15. Disconnect electrics between 11 m section and main boom;

➠ Electrical connection on the lattice extension – 11 m two-stage swing-away
lattice extension, p. 3-55.

4 9
93
16. Attach guide rope to the head of the 11 m section.
00
51

17. Remove left pin between 11 m section and main boom head;
➠ Pin connections on the main boom head, p. 3-39.

18. Swivel the lattice extension towards the main boom until the connec-
tion between the main boom (in the front area) and the 11 m section
engages; ➠ Swivelling the lattice extension during rigging, p. 3-46.
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Operating instructions for lattice extension 2 084 770 en 3 - 23
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

19. Secure 11 m section on the main boom with locking pin;

➠ Connections in the front area, p. 3-34.

20. Remove left pin between 11 m section and main boom head;
➠ Pin connections on the main boom head, p. 3-39.

21. Swivel the lattice extension on the run-up rail onto the main boom.

4 9
93

H If the 7 m section has been removed, proceed with point 23.

00
51

22. Establish both connections between 7 m section and main boom;

➠ Connections in the rear area, p. 3-37.
➠ Connections on the run-up railp. 3-36.

23. If the 7 m section has been removed, swivel the 11 m section on the
run-up rail onto the main boom and secure there with locking pin;
➠ Connections in the rear area, p. 3-38.
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3 - 24 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

24. Check whether the lattice extension is in transport position;

➠ Checking transport condition, p. 3-29.

25. Fold in the run-up rail; ➠ Folding run-up rail in/out, p. 3-32.

Further working steps for raising the boom; ➠ p. 3-63.

Telescoping with rigged lattice extension; ➠ p. 3-65.

4 9
93
00
51
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Operating instructions for lattice extension 2 084 770 en 3 - 25

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.4 Check lists for rigging work

4 9
93

Blank page
00
51

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3 - 26 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5 Description of rigging work

3.5.1 Preparing the truck crane for rigging

H The data in this section also applies to the rigging of the boom extension.

Do not override the SLI when lowering into a horizontal position!

If these requirements are met, lowering into the horizontal position with
lattice extension/boom extension and a slewing range of 360° is permitted
and monitored by the SLI; ➠ Raising and setting down the main boom with rig-
ged lattice extension, p. 3-63.

Requirements for Before you rig a lattice extension or the boom extension, the following

9
rigging requirements must be met:

4
– The two-stage swing-away lattice extension is attached to the side of
the main boom and is in transport condition.
93
– The counterweight version required according to the Lifting capacity table
for the planned operation with the lattice extension is rigged.
– The truck crane is supported with the prescribed outrigger span for the
00

planned operation with the lattice extension according to the Lifting ca-
pacity table and is aligned horizontally.
– The main boom is completely retracted and has been lowered into hori-
51

zontal position.
– The telescoping cylinder is locked in telescopic section IV and is retract-
ed as far as possible just before the start of rigging so that all teles-
coping parts are fully retracted.
– If the truck crane is equipped with two hoists with additional equip-
ment, the hook block is unreeved on the hoist which is not used for
working with the lattice extension.

Requirements for Before you lower a lattice extension or the boom extension into a horizon-
unrigging tal position, the following requirements must be met:

– No other load is raised apart from the hook block.

– The required counterweight version for operation with the rigged lattice
extension according to the Lifting capacity table is rigged.
– The truck crane is supported with the outrigger span prescribed for
operation with the rigged lattice extension according to the Lifting
08.05.2003

capacity table.

s
Operating instructions for lattice extension 2 084 770 en 3 - 27
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

– The main boom is fully retracted (0/0/0/0).

– The telescoping cylinder is locked in telescopic section IV and is retract-
ed as far as possible just before the start of rigging so that all teles-
coping parts are fully retracted.
– The SLI code is entered for operation with the rigged lattice extension.

Securing lattice If the truck crane is not well aligned, the lattice extension may swing out
extension with of its own accord when you remove the last connection that held the lat-
cord tice extension at the side of the main boom.

You must therefore secure the lattice extension before you begin with the
rigging work.

G
Risk of accidents from lattice extension swinging of its own accord
Always secure the lattice extension with a guide rope on the main boom
before removing any connections.
This will prevent the lattice extension from slipping off the run-up rail,

9
swinging around and knocking you off the carrier or injuring other per-
sons in the slewing range. 4
93
Secure the lattice extension as follows:
00

• Attach a cord (2) at the front of the lattice

extension.
• Guide the cord underneath the lattice ex-
51

tension, via the holding rod (1) on the

main boom and back again.
• Have a helper hold the cord tight whilst
you are removing the last connection.

H If you are alone, secure the other end of the cord on the crane (e. g. on the
steps of the access ladder leading to the carrier). Leave enough play in
the cord that it is tight only when you swing the lattice extension onto the
main boom head later on.
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3 - 28 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.2 Checking the transport condition

For transportation you must establish certain connections between both

parts of the lattice extension. The connections which need to be estab-
lished depend on whether the lattice extension:

– is folded up at the side of the main boom for transportation or

– is completely removed for transportation.
Transport condition is when the lattice extension has been removed as
described in the corresponding checklists.

S
Be careful not to damage the lattice extension and the main boom!
Always put the lattice extension into transport condition before driving
the truck crane with a lattice extension folded at the side or working with
the main boom.
Only then is the lattice extension secured against slipping.
This way you prevent the partly fastened lattice extension hitting the

9
main boom or the individual components of the lattice extension hitting
each other and becoming damaged.
4
93
You must check transport condition:
– After unrigging the lattice extension, before you drive the truck crane
00

with the lattice extension folded at the side or work with the main
boom.
– Before installation and before rigging the lattice extension.
51

The corresponding checklists require that the lattice extension is in

transport condition.

The following paragraphs and the diagram show the necessary connecti-
ons for the transport condition with the lattice extension folded at the side
and removed.
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Operating instructions for lattice extension 2 084 770 en 3 - 29
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

4 9
93
00
51

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3 - 30 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

Transport condi- The transport condition with the lattice extension folded at the side is
tion with lattice created when all of the following connections are established.
extension folded
at the side • Check the connections and establish them if necessary.
If 7 m section and 11 m section are folded at the side:
– The connection between 11 m section and main boom in the front area
is engaged (1) and the locking pin is inserted; ➠ Connections in the front
area, p. 3-33.
– The 7 m section is fastened to the run-up rail with a pin (6);
➠ Connections on the run-up rail, p. 3-36.
– The 7 m section and the 11 m section have been joined (2);
➠ Connections in the middle area, p. 3-35.
– The connections and those at the pivot point between the 7 m section
and the 11 m section have been established (3); ➠ Pin connections on the
lattice extension, p. 3-42.
– The 7 m section and main boom have been joined (4);
➠ Connections in the rear area, p. 3-37.
4 9
If the 11 m section alone is folded at the side:
93
– The connection between 11 m section and main boom in the front area
is engaged (1) and the locking pin is inserted; ➠ Connections in the front
00

area, p. 3-33.
– The connection between 11 m section and main boom in the rear area
is engaged (5); ➠ Connections in the rear area, p. 3-38.
51

If the 7 m section alone is folded at the side:

– The 7 m section is fastened to the run-up rail with a pin (6);
➠ Connections on the run-up rail, p. 3-36.
– The 7 m section and main boom have been joined (4);
➠ Connections in the rear area, p. 3-37.

Transport condi- The transport condition for the removed lattice extension is created when
tion with remo- all of the following connections are established.
ved lattice exten-
sion • Check the connections and establish them if necessary.
– The connections and that at the pivot point between the 7 m section
and the 11 m section have been established (3); ➠ Pin connections on
the lattice extension, p. 3-42.
– The 7 m section and 11 m section have been joined (2);
➠ Connections in the middle area, p. 3-35.
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Operating instructions for lattice extension 2 084 770 en 3 - 31

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.3 Folding the run-up rail out/in

The run-up rail is folded out for rigging and folded back in for on-road
driving after derigging.

Folding the run-up rail out

• Pull the locking bar (1) downwards against
the spring force, and out of the bore (3).
• Fold out the run-up rail to a small extent
and let go the locking bar.
• Fold out the run-up rail further until the
locking bar engages in the bore hole (2).

9
Folding the run-up rail in
4
• Pull the locking bar (1) downwards against
93
the spring force, and out of the bore (2).
• Fold out the run-up rail to a small extent
and let go the locking bar.
00

• Fold the run-up rail in until the locking bar

engages in the bore (3).
51

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3 - 32 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.4 Connections with folded lattice extension

The lattice extension is turned sideways to the main boom in folded position.
In this position there are four areas where various connections have to be
disconnected and reconnected again during rigging and unrigging:

– in the front area (1), behind the rope grab,

– in the middle area (2), above the derricking cylinder’s pivot point,
– on the run-up rail (3),
– in the rear area (4), in front of the crane engine.
In each area there are one or two bearing points that can be used for con-
necting parts to each other. Depending on the rigging mode and job, diffe-
rent parts of the lattice extension must be connected to each other or
connected to the main boom basic section.

G
Risk of accidents due to falling parts!

9
Always secure the pins both in the bearing points and in the holders
using retaining pins.
4
This prevents unsecured pins from becoming loose, falling out and cau-
93
sing injuries.
00

Connections in In the front area there is a connection between the 11 m section and the
51

the front area main boom.

This connection needs to be established if the lattice extension is folded

at the side of the main boom during unrigging or installation.
The connection must be removed before rigging or dismantling the lattice
extension.

Removing the connection

G
Risk of accidents from lattice extension swinging of its own accord
Always secure the lattice extension with a guide rope on the main boom
before removing any connections.
This will prevent the lattice extension from slipping off the run-up rail,
swinging around and knocking you off the carrier or injuring other per-
08.05.2003

sons in the slewing range.

s
Operating instructions for lattice extension 2 084 770 en 3 - 33
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

G
Risk of accidents from a falling lattice extension.
Be sure that the 11 m part is locked on the main boom head in the front
right, before you loosen the connection in the front area. This will prevent
the lattice extension from falling and causing injury to you or other per-
sons.

• Check if the 11 m-part is locked onto the

bearing points (6); ➠ p. 3-40.
• Remove the locking pin (5) from the bore
(4) in the bearing block (1), insert it in the
holder (5) and secure it with the retaining
pin.
• Lift the lever (3) and hold it. You must over-
come a spring force and friction force to
lift it.
• Push the spring latch (2) out and rest lever

9
on the spring latch.

4
If the lever is on the spring latch, the connec-
tion between lattice extension and basic sec-
93
tion is released.
00

Establishing connection
The two following points must be carried out
51

before you swivel the lattice extension onto

the run-up rail:
• Lift the lever (3) off the spring latch (2)
against the spring force and hold it.
• Push the spring latch in.
• Slowly yield to the spring force. The lever
moves down into the end position
• Swing the lattice extension onto the run-
up rail until the connection engages.
• Remove the locking pin (5) from the holder
(4),insert it in the bore in the bearing block
(1) and secure it with the retaining pin. The
connection is now established and secured.
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3 - 34 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

Connections in
the middle area
Connection between 7 m section and 11 m section
The connection must be made:
– for transportation,
– for installation and removal,
– when unrigging the 18 m two-stage swing-away lattice extension.

The connection must be disconnected:

– when rigging the 11 m swing-away lattice extension,
– when rigging the 18 m two-stage-swing-away lattice extension

Removing the connection

• Swivel the catch hook (3) out of the holder
(1) and into position A.
• Swivel the catch hook back to the attach-

9
ment point (4) into position B after you
4 have:
93
– swivelled the 11 m section in front of the
main boom in the course of rigging the
11 m swing-away lattice extension
00

or
– swivelled the 7 m section slightly away
from the 11 m section in the course of rig-
51

ging the 18 m two-stage swing-away lat-

tice extension.
Establishing connection
• Check whether the catch hook is in posi-
tion B.
• When unrigging the 11 m swing-away lat-
tice extension, swivel the 11 m section
onto the 7 m section – the catch hook (3)
engages behind the holder (1).
• When unrigging the 18 m two-stage swing-
away lattice extension, swivel the 7 m sec-
tion onto the 11 m section – the catch hook
(3) engages behind the holder (1).
08.05.2003

s
Operating instructions for lattice extension 2 084 770 en 3 - 35
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

Connections The 7 m section can be fastened to the run-up rail with a pin.
on the run-up rail
The connection must be made:
– when unrigging the 18 m two-stage swing-away lattice extension,
– for operation with the 11 m swing-away lattice extension.

The connection must be disconnected:

– when rigging the 18 m two-stage swing-away lattice extension,
– after operation with the 11 m swing-away lattice extension, if the
lattice extension is to be removed.

Establishing connection
• Swivel the entire 7 m section on the run-up
rail onto the main boom.
• Remove the pin (1) from the holder (2) and
use it to attach the 7 m section to the run-

9
up rail.

4
• Secure the pin with the retaining pin.
93
00
51

Removing the connection

• Pull the pin (1) out of the connection and
insert it into the holder (2).
• Secure the pin with the retaining pin. 08.05.2003

3 - 36 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

Connections in Connection between 7 m section and main boom

the rear area
The connection must be made:
– when unrigging the 18 m two-stage swing-away lattice extension,
– for operation with the 11 m swing-away lattice extension.

The connection must be separated:

– when rigging the 18 m two-stage two-stage swing-away lattice exten-
sion,
– for removing the 18 m two-stage swing-away lattice extension.

Removing the connection

G
Risk of accidents from falling 7 m section!
Make sure the connection is established at the pivot point between the
7 m section and the 11 m section (➠ p. 3-42), before you remove the con-
nection between the 7 m section and the main boom. This will prevent

9
the 7 m section from falling down when releasing the connection.
4
93
• Release the retaining pin and remove the
pin (1) from the bearing point (3).
• Insert the pin into the retaining sheet (2)
00

and secure it with a retaining pin.

51

Establishing connection
• Swivel the lattice extension into the main boom until the bearing point
(3) is aligned.
• Release the retaining pin and take one pin out of the retaining sheet (2).
• Insert the pin into the bearing points (3) and secure it with a retaining
pin.
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Operating instructions for lattice extension 2 084 770 en 3 - 37
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

H
Connection between 11 m section and main boom

This connection does not apply to truck cranes that are supplied with an
18 m two-stage swing-away lattice extension.

This connection must be established if the 11 m swing-away lattice exten-

sion is folded in to the side during unrigging.

The connection must be disconnected before the 11 m swing-away lattice

extension is swivelled onto the main boom head.

If the truck crane was supplied with an 11 m

swing-away lattice extension, the retaining
strut (1) will be on the holder (2) on the main
boom and secured there with a pin (3) and a
retaining pin.

9
The 11 m section is in the correct position for
4
establishing the connection if the connection
93
between 11 m section and main boom is en-
gaged in the front area.
00
51

Establishing connection
• Put the retaining strut (1) onto the bearing
point (5) on the 11 m section.
• Fasten the retaining strut with a pin (4) and
secure the pin with a retaining pin.

Removing the connection

• Loosen the retaining pin and remove the
pin (4).
• Insert the pin into the bore hole (6) and
secure it with a retaining pin.
For operation the retaining strut remains fa-
stened to the holder (2) with the pin (3).
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3 - 38 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.5 Pin connections on the main boom head

The lattice extension and main boom head are connected on the bearing
points using pins. The pins can be found in holders on the lattice extensi-
on and are secured there with retaining pins.

G
Risk of accidents due to falling parts!
Always secure the pins both in the bearing points and in the holders
using retaining pins. This prevents unsecured pins from becoming loose,
falling out and causing injuries.

G
Risk of accidents from lattice extension swinging of its own accord
Always secure the lattice extension with a guide rope before removing
any connections.
This will prevent the lattice extension from swinging around of its own
accord and causing injury to you or other persons.

4 9
G
93
Risk of accidents from a falling lattice extension!
Be sure that the connection between the 11 m section and the main boom
has engaged and is secure before you release the connection on the right
side of the main boom head. This will prevent the lattice extension from
00

falling and causing injury to you or other persons.

51

Connections on the left side

The connection needs to be established after the lattice extension has
been swivelled in front of the main boom head during rigging.

The connection needs to be removed so that the lattice extension can be

swivelled onto the main boom when it is on the run-up rail during unrig-
ging.

Connections on the right side

The connection needs to be established so that the lattice extension can
be swivelled in front of the main boom head for rigging.

The connection needs to be removed so that the lattice extension can be

08.05.2003

swivelled onto the main boom side during unrigging.

s
Operating instructions for lattice extension 2 084 770 en 3 - 39
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

Establishing For these connections you will find are three short pins and one long pin

H
connections in holders on the fixed part of the 11 m section.

The long pin is always placed last, into the bottom bearing point on the
left-hand side. Due to the lattice extension’s dead weight these bearing
points are not entirely in alignment and you cannot insert a short pin here.

Connections on the right side

• Swing the lattice extension onto main
boom head until the bearing points (1) and
(2) are in alignment.
• Remove the retaining pins and take the
two short pins (3) and (5) out of the hol-
ders (4).
• Insert the two pins into the bearing points
(1) and (2) and secure them with
retaining pins.

4 9
93
00

Connection on the left side

51

• Swing the lattice extension in front of the

main boom head until the bearing points
(1) and (2) are in alignment.
• Remove the retaining pins from the pins in
the holders (4).
• First, insert the short pin (3) in the upper
bearing point (1).
• Then hammer the long pin (5) into the
lower bearing point (2).
• Use retaining pins to secure the pins in the
bearing points.
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3 - 40 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

Remove • Secure the lattice extension with a guide rope before removing any con-
connections nections.

Connections on the left side

• Remove the retaining pins from pins (1)
and (2).
• First hammer the long pin (5) out of the
lower bearing point (2).
• Then hammer the short pin (3) out of the
upper bearing point (1).
• Insert both pins into the holders (4) and
secure them with retaining pins.

4 9
93
Connection on the right side

G
Risk of accidents from a falling lattice extension!
00

Make sure the connection between the 11 m section and the main boom
is engaged and secured before removing the connection on the right-
hand side. This will prevent the lattice extension from falling and causing
51

injury to you or other persons.

• Swivel the lattice extension onto the main

boom until the connection between the
11 m section and the main boom engages.
• Remove the retaining pins from pins in the
bearing points (1) and (2).
• Hammer the two pins out of the bearing
points.
• Insert both pins (3) and (5) into the holders
(4) and secure them with retaining pins.
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Operating instructions for lattice extension 2 084 770 en 3 - 41

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.6 Pin connections on the lattice extension

The 11 m section and the 7 m section are connected on the bearing points
using pins. The pins are inserted into the 7 m section, at the rear of the
retaining sheet on the upper boom.

G
Risk of accidents due to falling parts!
Always secure the pins both in the bearing points and in the holders
using retaining pins. This prevents unsecured pins from becoming loose,
falling out and causing injuries.

G
Risk of accidents from 7 m section swinging of its own accord
Always secure the 7 m section with a guide rope before removing any
connections.
This will prevent the 7 m section from swinging around of its own accord
and causing injury to you or other persons.

4 9
G
93
Risk of accidents from falling 7 m section!
Be sure that the connections between the 7 m section and the main boom
(in the rear area) and between the 7 m section and the run-up rail have
been made before you release the connection on the right side of the pi-
00

vot point. In this way, you prevent the 7 m section from falling when this
connection is released and causing injury to you or others.
51

Connection on the left side

The connection needs to be established after the 7 m section has been
swivelled in front of the 11 m section during rigging.

The connection needs to be removed so that the 7 m section can be fol-

ded at the side of the 11 m section during unrigging.

Connection at the pivot point, on the right side

This connection must be established if the 11 m swing-away lattice exten-
sion is unrigged and the 7 m section is attached to the main boom.

This connection must be removed if the 11 m swing-away lattice extensi-

08.05.2003

on is rigged and the 7 m section is attached to the main boom.

3 - 42 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

Connection on • Swivel the 7 m section in front of the 11 m section until the bearing
the left side points on the left side are in alignment.

Establishing connection
• Loosen the retaining pins and remove the
pins from the top of the retaining plate (1).
• Then insert the two pins and into the bea-
ring points (2) and (3) on the left side and
secure the pins with retaining pins.
Removing the connection
• Remove the retaining pins and take the
pins out of the bearing points (2) and (3)
on the left side.
• Insert both pins into the retaining sheet (1)
and secure them with retaining pins.

4 9
93
00

Connection on Before removing this connection, you need to have connected

the pivot point, the 7 m section with the main boom basic section and the 7 m section
51

on the right side with the run-up rail; ➠ Connections on the run-up rail, p. 3-36;
➠ Connections in the rear area, p. 3-37.
Removing the connection
• Remove the retaining pins and take the
pins out of the bearing points (1) and (2)
on the pivot point.
• Insert both pins into the retaining sheet (3)
and secure them with retaining pins.
Establishing connection
• Loosen the retaining pins and remove two
pins from the top of the retaining sheet (3).
• Insert pins into bearing points (1) and (2)
at the pivot point.
• Secure the pins using retaining pins.
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Operating instructions for lattice extension 2 084 770 en 3 - 43

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

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3 - 44 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.7 Swivelling lattice extension onto the main boom head

This section describes how the lattice extension is swung

– onto the main boom head for rigging and
– onto the main boom basic section for unrigging.
The lattice extension must be swung onto the main boom head from
transport position so that the 11 m section can be fastened to the right
side of the main boom head with pins.

Requirements – The lattice extension is in transport position when the lattice extension
is folded at the side; ➠ Checking transport condition, p. 3-31.
– In the middle area, the required connections are loosened on the run-
up rail and in the rear area.
– The connection is established in the front area; ➠ Connections in the
front area, p. 3-34.

G
Risk of accidents from a falling lattice extension!
Be sure that the connection is established in the front area, before you

9
slew the lattice extension onto the main boom head. This will prevent the
4
lattice extension from falling when slewing and causing injury to you or
other persons.
93

Swinging lattice
00

extension

When swung, the lattice extension rolls on the run-up rail, turns around
51

the connection in the front area (2) and becomes makes contact at the
front at the bearing points (1).

• When rigging pull the lattice extension at the back away from the basic
section until it is at the front and the bearing points (1) are aligned;
➠ p. 3-39.
• When unrigging, push the lattice extension onto the run-up rail until the
connection between the 11 m section and the main boom engages.
Secure the connection with the retaining pins; ➠ Connections in the front
area, p. 3-33.
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Operating instructions for lattice extension 2 084 770 en 3 - 45

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.8 Swivelling the lattice extension when rigging

H This section describes the swinging of the lattice extension during rig-
ging. If you want to swing the lattice extension for unrigging, proceed in
the opposite order.

When rigging the 11 m swing-away lattice extension and the 18 m two-

stage swing-away lattice extension, you have to swing the 11 m section in
front of the main boom head.

To rig the 18 m two-stage swing-away lattice extension you must also

swivel the 7 m section in front of the 11 m section.

4 9
93
Swinging the Requirements:
00

11 m section in
– The lattice extension has been swivelled onto the main boom head.
front of the main
boom ➠ Swivelling the lattice extension onto the main boom head, p. 3-45.
51

– The 11 m section is fastened to the right side of the main boom head;
➠ Pin connections on the main boom head, p. 3-39.
– The lattice extension is secured on the head of the 11 m section with a
guide rope; ➠ Securing lattice extension with cord, p. 3-28.

G
Risk of accidents from lattice extension swinging of its own accord
Always secure the lattice extension with a guide rope before you swing it
from the run-up rail. Make sure that there are no people or objects in the
slewing range of the lattice extension and always swing out the lattice
extension off the ground using a guide rope.

• Disconnect the connection between the 11 m section and the main

boom; ➠ Connections in the front area, p. 3-33.
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GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

If a helper is holding the guide rope, he can now pull the lattice extension
from the run-up rail and swing it in front of the main boom head.

If you are alone and have attached the guide rope to the crane when
securing, the lattice extension will now only swing until the guide rope is
tight.
You can now use the guide rope to swing the lattice extension off the
floor and in front of the main boom head with.

Proceed in the opposite order for unrigging.

Swivelling the Requirements

7 m section in
– The 11 m section is fastened in front of the main boom head with a pin;
front of the 11 m
section ➠ Pin connections on main boom head, p. 3-39.
– The lattice extension is secured on the head of the 7 m section with a
guide rope.

9
• Remove the connection between the 7 m and 11 m section; ➠ Connec-
4
tions in the middle area, p. 3-35.
93
• Turn the 7 m section in front of the head of the 11 m section using the
guide rope.
00

Proceed in the opposite order for unrigging.

51
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GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.9 Adjusting angle on the lattice extension

You can set three different angles for the lattice extension (0°, 20° and 40°).
To set the angles, attach the lattice extension to the hoist cable and in-
cline by means of the hoist. The degree of the angle is determined by

H
securing pins, which are inserted or removed at the respective places.

If the length of lattice extension and the SLI permit it, you can also place
the lattice extension on the ground in order to make the pin connections.
In this case, the inclination sets itself during the raising of the main boom.

G
Risk of accidents and damage when inclining!
If the lattice extension is inclined in an incorrect fashion, it can lead to
accidents and to damage to the lattice extension and the hoist cable.
Therefore, only proceed according to the following instructions when in-
clining the lattice extension and observe all safety instructions.

Attaching lattice For rigging you need to attach the lattice extension to the hoist cable if it

9
extension to is to be inclined.
hoist cable 4
For unrigging you need to attach the lattice extension to the hoist cable in
93
order to pull the inclined lattice extension up to the 0° inclination.
• Guide the hoist cable over the deflection
sheave on the fixed part of the 11 m sec-
00

tion, along the left side of the lattice exten-

sion and up to the connection eye (1).
51

• Attach the cable end clamp (2) to the con-

nection eye.
• Place the hoist cable on the top of the lat-
tice extension in such a way that it cannot
become caught up.

S
Risk of damaging the hoist cable!
Always guide the hoist rope via the folded out deflection sheave in the
11 m section when you are attaching the lattice extension to the hoist
cable for adjusting the angle. This will keep the hoist cable from scraping
the lattice extension and prevent the forces in the hoist cable from in-
08.05.2003

creasing to an extent that would damage it due to the unfavourable angle.

3 - 48 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

S
Risk of damage during telescoping!
Avoid telescoping the main boom as long as the hoist cable is attached to
the lattice extension. If telescoping is absolutely necessary, make sure
hoist cable will not tear by giving it sufficient slack.

Adjusting the This section decribes the procedure for adjusting the angle.
angle The required pin connections for the different angles are illustrated in the
following section; ➠ Pin connections for the angles, p. 3-50.

When rigging
• Lift the lattice extension with the hoist cable until the weight is taken off
the securing pins.
• Remove the retaining pins and knock out the securing pins; ➠ p. 3-50.
• Establish the pin connections required for this angle and secure all secu-
ring pins with retaining pins; ➠ p. 3-50.
• Incline the lattice extension with the hoist into the required angle.

9
When unrigging
4
• Using the hoist cable, pull the lattice extension to a 0° angle.
93
• Give a little more hoist cable and lower the main boom if necessary for
better access to the pin connections.
00

• Remove the retaining pins and knock out the securing pins; ➠ p. 3-50.

S
Risk of damaging the hoist cable when lowering!
51

If you have pulled the lattice extension as far as possible into the 0° posi-
tion with the hoist cable, you always have to leave some hoist cable be-
fore you lower the main boom. In this position the lattice extension can
no longer compensate the radius modification by inclining, the hoist
cable is weighted when lowered and may tear.

• Make the necessary pin connections for the 0° angle and secure all se-
curing pins with retaining pins.
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s
Operating instructions for lattice extension 2 084 770 en 3 - 49
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

Pin connections On each side there is a retaining pin in the strut above the point of adjust-
for the angle ment which is used for setting the angle of inclination.
The retaining pins are inserted into different bores, depending on the de-
gree of inclination of the lattice extension.

G
Risk of accidents from lattice extension folding down!
Always secure the lattice extension with the hoist cable before you knock
out pins for the angle. This will prevent the lattice extension suddenly
folding down and injuring you or other people.

0° angle
On both sides the securing pins are inserted
into the bores (1) and secured with securing
pins.
The bores (2) remain open.

4 9
93
20° angle
On both sides the securing pins are inserted
into the bores (2) and secured with securing
00

pins.
The bores (1) remain open.
51

40° angle
On both sides the bores (1) and (2) remain
free. The securing pins are inserted in the
holders (3) and are secured with retaining
pins.

G
Risk of accidents from non-secured securing pins!
Always secure the securing pins in the holders (3) with retaining pins.
This prevents the non-secured pins from falling out of the holders and
causing injuries.
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GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.10 Folding deflection sheave on 11 m section out/in

To prevent the hoist cable dragging on the main boom or the lattice exten-
sion during operation with the lattice extension, the hoist cable is guided
via a deflection sheave.
You need to fold the deflection sheave out for operation with the lattice
extension as well as for operation with the boom extension.
For transportation, fold the deflection sheave back in again.

G
Risk of crushing!
Always hold the deflection sheave by the crosshead on the top when
removing the pin. You might get your fingers crushed if you hold the
sheave by the side plate.

Folding out deflection sheave

• Slightly raise deflection sheave, holding it
by the crosshead (1), to take some of the

9
weight off the pin in the bore (2) – see pic-

4 ture below.
• Pull the pin out of the bore (2).
93
• Fold the deflection sheave up and secure it
with the pin in the bore (3).
00

• Secure the pin with a retaining pin.

51

Folding in deflection sheave

• Slightly raise deflection sheave, holding it
by the crosshead (1), to take some of the
weight off the pin in the bore (3) – see pic-
ture above.
• Pull the pin out of the bore (3).
• Fold the deflection sheave down and se-
cure it with the pin in the bore (2).
• Secure the pin with a retaining pin.
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Operating instructions for lattice extension 2 084 770 en 3 - 51

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.11 Positioning/removing the hoist cable

G
Risk of accidents due to falling parts!
Always secure the hoist cable holding rollers and rods with retaining pins.
This prevents elements coming loose, falling down and injuring people.

When setting an When setting an angle of 40° or 20°, positioning and removing the hoist
angle of cable is done in two steps:
20° or 40°
For positioning:
– Begin by placing hoist cable over deflection sheave in the fixed part of
the 11 m section only and attach to front of the connection eye.
– After having set the angle, disconnect hoist cable from connection eye

9
and guide over the front deflection sheave and head sheave.

4
93
For removal:
– Begin by removing hoist cable from head sheave and front deflection
00

sheave and fasten to connection eye.

– After having set 0° angle, disconnect hoist cable from connection eye
and take it off the deflection sheave in the fixed part of the 11 m section.
51

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GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

11 m swing-away lattice extension

18 m two-stage swing-away lattice extensi-

on

9
Positioning hoist • Remove the hoist cable holding rollers and rods (1).
rope
4
• Guide the hoist rope via the deflection sheaves (4), (3) and via the head
93
sheave (2) on the 11 m section or on the 18 m section.
• Put all hoist cable holding rollers and rods back in place and secure
these with retaining pins.
00

• Attach the hook tackle or the hook block. The hoist rope may now, de-
pending on the length of lattice extension, be reeved once or twice;
➠ p. 3-54.
51

Removing hoist • Unreeve the hook block.

cable
• Remove the hoist cable holding rollers and rods (1).
• Take the hoist cable off the head sheave (2) and the deflection sheaves
(4), (3) and place it onto the ground on the left side.
• Put all hoist cable holding rollers and rods back in place and secure
these with retaining pins.
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Operating instructions for lattice extension 2 084 770 en 3 - 53
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

Possible reeving The hoist cable can be reeved once or twice;

methods on the
swing-away
lattice extension

Hook tackle, max. lifting capacity 8 t 1 fall

max. lifting capacity with the GMK 5100:

for simple reeving 7 t (15.432 lbs)

1 sheave hook block, max. lifting capacity 20 t 1 fall 2 fall

4 9
max. lifting capacity with the GMK 5100
for simple reeving 7 t (15.432 lbs)
93
for double reeving 14 t (30.864 lbs)
00
51

The hoist cable can be reeved at the most twice on the 11 m swing-away
lattice extension.

On the 18 m two-stage swing-away lattice extension and on the 26/34 m

boom extension the hoist cable can only be reeved once.

Reeving the hoist rope into the hook block; ➠ GMK 5100 Operating Instruc-
tions, part 2 Superstructure – Rigging work.
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GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.12 Electrical connection on the lattice extension

The SLI, the lifting limit switch and the lowering limit switch are connec-
ted via the electrical connection on the lattice extension.

11 m swing-away For the 11 m swing-away lattice extension the electrical connection is

lattice extension made or disconnected on the right side of the main boom head.

Establishing electrical connection

• Remove the short-circuit plug (3) from the
socket (4) on the main boom and plug it in
the dummy socket (5).
• Unwind the cable from the roll (6).
• Remove the plug (2) from the dummy
socket (1) and insert it in the socket (4) on
the main boom head.

4 9
93
00
51

Disconnecting electrical connection

• Remove the plug (2) from the socket (4) on
the main boom head and insert it in the
dummy socket (1) on the 11 m section.
• Remove the short-circuit plug (3) from the
socket (5) and plug it in the socket (4) on
the main boom.
• Wind the cable onto the roll (6).
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Operating instructions for lattice extension 2 084 770 en 3 - 55
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

• Check if the dummy plug (2) is inserted in

the socket (1) at the front of the 11 m
section.

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93
00
51

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GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

18 m two-stage For the 18 m swing-away lattice extension an additional connection is

swing-away latti- made or disconnected between the 11 m section and the 7 m section as
ce extension well as the electrical connection of the 11 m swing-away lattice extension.

• First make the electrical connection for the 11 m swing-away lattice

extension; ➠ p. 3-55.

Establishing electrical connection

• Remove the plug (3) from the dummy
socket (1) on the 7 m section.
• Unwind the cable from the roll (5).
• Remove the dummy plug (2) from the sock-
et (4) on the 11 m section and insert it in
the dummy socket (1) on the 7 m section.
• Insert the plug (3) in the socket (4) on the
11 m section.

4 9
93
00

Disconnecting electrical connection

51

• Remove the plug (3) from the socket (4) on

the 11 m section.
• Remove the dummy plug (2) from the dum-
my socket (1) on the 7 m section and insert
it in the socket (4) on the 11 m section.
• Insert the plug (3) in the dummy socket on
the 7 m section.
• Wind the cable onto the roll (5).
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GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.13 Lifting limit switch on the lattice extension

The functions Raise hoist, extend main boom, extend main boom and Lower main
boom are monitored during operation with the lattice extension by the
lifting limit switch on the lattice extension and are switched off when the

H
lifting limit switch is actuated.

The same lifting limit switch is used for lattice extension and main boom.

Overriding con- For operation with the lattice extension you must remove the lifting limit
nection on main switch on the main boom and override the connection.
boom
• Insert the short-circuit plug (1) in the
socket for the connection of the lifting limit
switch.
The connection is now overridden.

4 9
93
00
51

On 11 m swing-
away lattice
extension
• Place the lifting limit switch (3) in the hol-
der (4) and secure it with a retaining pin.
• Remove the short-circuit plug (2) from the
socket (1).
• Connect the lifting limit switch on the sock-
et (1).

• When unrigging you must insert the short-

circuit plug (2) back in the socket (1).
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GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

On the 18 m two-
stage swing-

H
away lattice ex-
tension

For operation with the 18 m two-stage swing-away lattice extension the

connection for the lifting limit switch on the 11 m section must be overrid-
den with a short-circuit plug.

• Place the lifting limit switch (2) on the

shackle (1) and secure it with a retaining
pin.
• Connect the lifting limit switch on the
socket (3).

• When unrigging close the socket (3) with

the protective cap.

4 9
93
00
51
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GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.14 Anemometer on the lattice extension

H
On 11 m swing-away
The same anemometer is used for lattice extension and main boom.

lattice extension
• Attach the anemometer (3) to the holder
(2) on the head of the 11 m section and
secure it with a retaining pin.
• Insert the plug (1) of the connecting cable
in the distribution box on the head of the
11 m section.
• Check for freedom of movement.
The anemometer must return to a vertical
position after being swung outwards.

9
• When unrigging close the socket on the
distribution box with the protective cap.
4
93
00

On the 18 m two-
stage swing-away
51

lattice extension
• Attach the anemometer (1) to the holder
(2) on the head of the 7 m section and se-
cure it with a retaining pin.
• Insert the plug (3) of the connecting cable
in the distribution box on the head of the 7
m section.
• Check for freedom of movement.
The anemometer must return to a vertical
position after being swung outwards.
• When unrigging close the socket on the
distribution box with the protective cap.

H
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You must remove the anemometer before unrigging the lattice extension.

3 - 60 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

3.5.15 Transportation on a separate vehicle

G
Only attach the lattice extension in such a way that it is positioned in the
centre of gravity and always use lifting gear with sufficient lifting capaci-
ty. This prevents the lattice extension falling and injuring people while
loading; ➠ Centre of gravity positions for slinging, p. 3-4.

• Check that all the required connections for transport condition are
established; ➠ Checking transport condition with removed lattice extension,
p. 3-31.

• For transportation, place the lattice exten-

sion on the skid (1) at the front and onto
the lower cross strut (2) at the rear of the

9
11 m section.
• Always secure the lattice extension on the
4 separate vehicle with belts as well to pre-
93
vent slipping and overturning.
00
51

S
Risk of damaging the lattice extension!
Always secure the lattice extension by tying it down with suitable belts
when it is transported on a separate vehicle. This prevents the two-stage
swing-away lattice extension tipping and becoming damaged during
transportation.
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GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.5 Description of rigging work

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3 - 62 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.6 Raising and setting down the main boom with rigged lattice extension

3.6 Raising and setting down the main boom with rigged

H
lattice extension

The information in this section also applies to raising and setting down

H
the main boom with a rigged boom extension.

To raise and set down the main boom with a rigged lattice extension the
main boom must be fully retracted because the SLI then automatically
switches to the rigging program.

To raise and set down, the following requirements must be met:

– The SLI code for the actual rigging mode is set on the SLI with the
rigged lattice extension; ➠ GMK 5100 Operating Instructions, part 2
00== Superstructure – Crane operation.

9
– The current reeving of the hoist cable on the lattice extension is entered.
! 4
– Apart from the hook block there is no load on the lattice extension.
93

• Derrick in the main boom to raise.

00

• Derrick out the main boom to set down.

51
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Operating instructions for lattice extension 2 084 770 en 3 - 63

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.6 Raising and setting down the main boom with rigged lattice extension

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93

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3 - 64 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.7 Telescoping with rigged lattice extension

3.7 Telescoping with rigged lattice extension

S
The main boom may become overloaded!
If you telescope the main boom with a rigged lattice extension or boom
extension, you must not rotate the superstructure at the same time.
This prevents the main boom becoming subject to additional side forces
and increased vibration and becoming overloaded.

H The information in this section also applies to telescoping with a rigged

boom extension.

Telescoping with a load is released by the SLI only for loads which are be-
low the values of the rigging programmes.
Telescoping with a rigged lattice extension is released by the SLI only if
the main boom is raised to an angle of approx. 75° - 80° (the exact angle
depends on the length of the lattice extension ➠ Rigging programs in the

9
lifting capacity table).
4
If the main boom angle is too small for telescoping with the rigged lat-
tice extension angle, the SLI shows the corresponding error message.
93
• Put down the load.
• Raise the main boom to an angle necessary according to the rigging
00

program (➠ Rigging programs in the lifting capacity table).

• Telescope the main boom to the required length and observe the hook
51

block when doing so; lower and raise it using the hoist.
Do not actuate the slewing gear when telescoping.
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Operating instructions for lattice extension 2 084 770 en 3 - 65

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.7 Telescoping with rigged lattice extension

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3 - 66 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.8 Operation with the lattice extension

H
3.8 Operation with the lattice extension

The information in this section also applies to operation with the boom ex-
tension. Observe the following safety instruction before working with the
boom extension.

G
Risk of overturning when working with the boom extension!
While you are working with the boom extension, make sure there is no
hook block reeved on the main boom.
It is not permitted to work with the main boom if the boom extension is
rigged.

H If a hook block is reeved on the main boom during operation with the lat-
tice extension, the loads given in the Lifting capacity tables decrease. The
values which must be deducted from the load capacities depend on the
length of the lattice extension and the weight of the hook block and are

H 9
entered in their own table in the Lifting capacity tables.

4
The hoisting, lowering, slewing, derricking and telescoping movements
93
of the main boom are done in the same way as when operating with the
main boom. Telescoping is permitted only at main boom angles of
approx. 75-80°, depending on the length of the lattice extension (exact va-
00

lue ➠ Rigging programs in the lifting capacity table).

51

3.8.1 SLI shutdown

Operation with the lattice extension and the boom extension is monitored
by the SLI.
During work with the lattice extension, an SLI shutdown may occur for the
same reasons as applied to operation with the main boom; ➠ Operating
instructions GMK 5100, 2 Superstructure – Crane operation.
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Operating instructions for lattice extension 2 084 770 en 3 - 67
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.8 Operation with the lattice extension

3.8.2 Procedure if the permissible wind speed is exceeded

Strong winds lead to the truck crane being overloaded. Closely observe
therefore the instructions in the operation instructions GMK 5100;
➠ Operating instructions GMK 5100, Part 2 Superstructure – Crane operation –
External influences during crane operation.

If the maximum wind speed according to the Load bearing capacity

table is exceeded, proceed as follows:

for wind speeds or wind speeds

up to 20 m/s over 20 m/s

• Put down the load. • Put down the load.

• Turn the superstructure in such • Completely retract the main

a way that the main boom provi- boom.
des the wind with as little wor-
king surface as possible. • Set the lattice extension down.

4 9
93
00
51

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3 - 68 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.9 Turning loads with the lattice extension

3.9 Turning loads with the lattice extension

When turning loads it is necessary to employ a two-hook operation.
The only type of two-hook operation technically possible and protected by
the SLI is described in this chapter using the turning of loads as an examp-
le.

G
Risk of accidents due to overloading!
Lifting a load with two hooks is permissible only if the following instruc-
tions and illustrations are observed!
If these instructions are not observed, accidents could occur due to indivi-
dual parts of the truck crane being overloaded! The SLI then no longer
provides protection.
Two-hook operation with the boom extension is not permitted!

G
Risk of accidents due to overloading!
The load must always be lifted completely with the weakest part first

9
(lattice extension).

4
H
93

You can find the position and function of the required operating instru-
00

ments in the supplied Operating Instructions for the GMK 5100.

51

3.9.1 Requirements

The following description requires that:

– the main hoist cable is reeved on the main boom and
– the auxiliary hoist cable is reeved on the lattice extension.
– the lifting limit switches for both hoisting gears are connected.

G
Risk of accidents due to overloading!
The reeving on the main boom must be equal to or greater than that on
the lattice extension!
If this condition is not fulfilled, the main hoist cable and main hoisting
gear will become overloaded.
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s
Operating instructions for lattice extension 2 084 770 en 3 - 69
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.9 Turning loads with the lattice extension

3.9.2 Setting SLI

H
For two-hook operation, both hoists must be activated on the SLI.

It is advisable to enter the reevings for both hoists at the start. The values
are stored and called up directly when switching hoisting gears. This eli-
minates the need for input later during operation. Proceed as follows:

• Switch off both hoists.

Cü To do this, press down both rocker switches Auxiliary hoist shutdown and
Main hoist shutdown.
• Switch on the main hoist.
ü To do this, push up the rocker switch Main hoist shutdown.
Lamp I for the main hoist lights up in the Hoists indicator lamps.

4 9
93
• In the display Reeving, enter the quantity of reeved cable of the main
§ hoist cable on the main boom.
00

Now the reeving for the main hoist is stored and you can switch to the au-
xiliary hoist.
51

• Switch off both hoists.

Cü To do this, press down both rocker switches Auxiliary hoist shutdown and
Main hoist shutdown.
• Switch on the auxiliary hoist.
C To do this, push up the rocker switch Auxiliary hoist shutdown.
On the indicator lamps Hoists, lamp II is flashing for the auxiliary hoist.

• In the display Reeving, enter the quantity of reeved rope on the auxiliary hoist
! cable of the lattice extension.
Now the reeving for the auxiliary hoist is also stored and you can switch
on the main hoist.
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3 - 70 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.9 Turning loads with the lattice extension

• Switch the main hoist on by pressing the Main hoist shutdown rocker
ü switch up.
On the display lamps Hoists, lamp II is now lit for the auxiliary hoist and
lamp I is flashing for the main hoist.

• Set the SLI code for operation with the telescopic swing-away lattice ex-
11== tension which is valid for the current rigging mode of the truck crane.
The SLI is thus set for two-hook operation; it now takes into consideration
the reeving for the auxiliary hoist and the lifting capacity tables for the lat-

H
tice extension.

In two-hook operation the loads given in the Lifting capacity table are redu-

9
ced by the weight of both reeved hook blocks.
4
93
00

Turning a load To turn loads, proceed only in the manner described as follows.

S
Keep the acceleration force as low as possible during two-hook operation.
51

Therefore move the load at the lowest possible speed!

H If the load is on two hooks, there will be slight differences in the Actual
load display. However, the differences are on the safe side with regard to

H
SLI shutdown.

If the load is on two hooks, you must not change the SLI code to Operation
with main boom; it must be set to Operation with the lattice extension through-
out the lifting process.
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s
Operating instructions for lattice extension 2 084 770 en 3 - 71
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.9 Turning loads with the lattice extension

C0183

9
• Lift the load fully with the lattice extension.

4
• Only now should you attach the load to the hook block of the main
boom as well.
93
• Now lift the load with the hook block on the main boom until both sling-
ing points are at the same height.
00
51

C0184

• Slacken the hoist cable on the lattice extension until the load is only
hanging from the hook block on the main boom.
08.05.2003

Turning the load is thus completed.

3 - 72 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed

3.10 Driving with rigged crane and lattice extension installed

This section describes how you can move the truck crane with an installed
counterweight and rigged lattice extension.

G
Risk of accidents!
It is forbidden to move the truck crane with a load on the hook.
Put the load down before you move the truck crane.
Secure the hook block so that it cannot swing.

G
Risk of overturning!
Before a rigged crane can be driven, the superstructure must be locked
and the slewing gear permanent brake must be engaged.

3.10.1 Driving route 4 9

93
The route must be a flat, even surface. The level adjustment system can-
not compensate for uneven surfaces. If the surface pressure of the tyres
00

exceeds the permissible load on the ground, the surface pressure must be
increased using packing made of durable material (e.g. wooden planks).

S
51

Risk of tyre damage!

Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ GMK 5100 Operating Instructions, part 1 Carrier – Technical data.
Do not reduce the tyre pressure!
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Operating instructions for lattice extension 2 084 770 en 3 - 73
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed

3.10.2 Position of the boom

The vehicle may only be moved if certain conditions are met. The boom
may have to be moved to a specified position, depending on the installed
counterweight.

S
Damage may occur to the axle lines!
Always move the boom to the prescribed position before you move the
rigged truck crane. The permitted load on the axle lines will be exceeded
if the boom is in a position which deviates from the prescribed position.

• Set the appropriate SLI code for the rigging mode on the safe load indi-
00== cator. The SLI codes can be found in the Lifting capacity table.

• Move the boom into the prescribed position. The prescribed boom posi-
tion can be found in the following tables.

G 9
Risk of accidents if SLI is overridden!
4
Always set the SLI rigging code corresponding to the current rigging
93
mode when you derrick the main boom into the prescribed position. Do
not override the SLI; the prescribed positions in the following tables are
all within the areas permitted according to the Lifting capacity tables.
00

The truck crane safe load indicator does not function when the SLI is over-
ridden!
51

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3 - 74 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed

11 m swing-away The following table only applies if the 11 m swing-away lattice extension
lattice extension is rigged. Tables applying if 18 m two-stage swing-away lattice extension
is rigged; ➠ p. 3-76.
Tables applying if boom extension is rigged; ➠ p. 4-21.

H
Counter Telescoping
The axle loads specified in the following tables refer to a driving mode
with the basic unit and 8 t hook tackle reeved on the lattice extension,
hook blocks must be unreeved.

Main Main Axle load 2) Axle load 2)

weight telescope section boom boom in t x 1000 lbs
in t I/II/III/IV inclination position1)
in ° front rear front rear

7.0 0/0/0/0 20 front 10.5 12.5 23.2 27.6

0/0/0/0 80 rear 11.0 12.0 24.3 26.5
11.0 0/0/0/0 20 front 10.0 15.5 22.1 34.2

9
0/0/0/0 80 rear 12.5 12.0 27.6 26.5
20.0 0.5 / 0.5 / 0 / 0 20 4
front 14.0 14.0 30.9 30.9
93
0/0/0/0 70 rear 14.0 14.0 30.9 30.9
24.0 0.5 / 0.5 / 0 / 0 20 front 13.0 17.0 28.7 37.5
0/0/0/0 60 rear 14.0 16.0 30.9 35.3
00

31.0 0.5 / 0.5 / 0.5 / 0.5 20 front 14.5 18.5 32.0 40.8
0/0/0/0 60 rear 16,0 16,5 36.4 36.4
51

1)
Boom position at rear = 0° position, boom over truck crane rear edge
Boom position at front = 180° position, boom over driver’s cab
2)
The indicated values apply to a 20° inclination of the lattice extension.
For other inclinations the values change slightly.
Axle load front: on the 1st, 2nd and 3rd axle line respectively
rear: on the 4th and 5th axle line respectively
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Operating instructions for lattice extension 2 084 770 en 3 - 75
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed

18 m two-stage The following table only applies if the 18 m two-stage swing-away lattice
swing-away latti- extension is rigged.
ce Tables applying if 11 m two-stage swing-away lattice extension is rigged;
extension ➠ p. 3-75.
Tables applying if boom extension is rigged; ➠ p. 4-21.

H
Counter Telescoping
The axle loads specified in the following tables refer to a driving mode
with the basic unit and 8 t hook tackle reeved on the lattice extension,
hook blocks must be unreeved.

Main Main Axle load 2) Axle load 2)

weight telescope section boom boom in t x 1000 lbs
in t I/II/III/IV inclination position1)
in ° front rear front rear

7.0 0/0/0/0 20 front 11.0 11.5 24.3 25.4

0/0/0/0 80 rear 11.0 12.0 24.3 26.5
11.0 0/0/0/0 20 front 10.5 15.0 23.2 33.1

9
0/0/0/0 80 rear 12.0 12.5 26.5 27.6
20.0 0.5 / 0.5 / 0 / 0 20 front 4 14.5 13.0 32.0 28.7
93
0/0/0/0 70 rear 13.5 14.5 29.8 32.0
24.0 0.5 / 0.5 / 0 / 0 20 front 14.0 16.0 30.9 35.3
0/0/0/0 70 rear 15.0 15.0 33.1 33.1
00

31.0 0.5 / 0.5 / 0.5 / 0.5 20 front 15.5 17.0 34.2 37.5
0/0/0/0 65 rear 16.5 16.0 36.4 35.3
51

1)
Boom position at rear = 0° position, boom over truck crane rear edge
Boom position at front = 180° position, boom over driver’s cab
2)
The indicated values apply to a 20° inclination of the lattice extension.
For other inclinations the values change slightly.
Axle load front: on the 1st, 2nd and 3rd axle line respectively
rear: on the 4th and 5th axle line respectively
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3 - 76 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed

3.10.3 Driving the rigged crane

Locking the su- Before the truck crane is moved, the superstructure must be locked to the
perstructure and carrier; ➠ GMK 5100 Operating Instructions, part 2 Superstructure – Crane
engaging the sle- operation.
wing gear perma-
nent brake
• Lock the superstructure; the indicator lamp Superstructure locked must be
! lit.
• Apply the slewing gear permanent brake and switch off the Slewing func-
Y tion to prevent inadvertent operation.
To do this push down the Slewing gear permanent brake rocker switch.
The Slewing gear permanent brake applied indicator lamp lights up when

H
the slewing gear permanent brake is applied.

If the crane engine stops the slewing gear permanent brake is automa-
tically applied.

9
• Retract the outrigger cylinders until the wheels are just above the
Retracting the
outrigger ground.
4
93

G
Risk of overturning!
Make sure that the truck crane does not overturn when the outriggers are
00

being retracted!
Retract all the outrigger cylinders as uniformly as possible!
51

Switching over
the suspension
locking system
• Switch the suspension locking system off. To do this push up the
u Suspension locking system rocker switch. The Suspension locking system indi-
cator lamp must go out.
• Retract the outrigger cylinders until the truck crane is approximately at
on-the-road level.
• Switch the suspension locking system back on again. To do this push
u down the Suspension locking system rocker switch. The Suspension locking
system indicator lamp lights up when the suspension system is locked.
• Continue to retract the outrigger cylinders.

G
Risk of overturning!
To reduce the risk of the crane overturning do not raise the outrigger
pads more than 5 to 10 cm off the ground. Leave the outrigger beams ex-
08.05.2003

tended.

s
Operating instructions for lattice extension 2 084 770 en 3 - 77
GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed

Switch on sepa- Before driving with the rigged crane you must switch on the separate
rate steering steering:

• Switch on the Level adjustment system key switch.

C0018

• Switch on separate steering by releasing the Separate steering rocker

b switch and pressing it down.

S
Damage may occur to steering linkage!
Before driving with the rigged crane always switch on separate steering
and steer the truck crane only when the vehicle is moving.
If separate steering is switched off or if you steer with the vehicle sta-
tionary the steering linkage may become damaged.

4 9
93
Driving

S
00

Risk of tyre damage!

Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
51

levels; ➠ GMK 5100 Operating Instructions, part 1 Carrier – Technical data.

Do not reduce the tyre pressure!

H The wind speed must be checked before the rigged truck crane is moved!
The same maximum permissible wind speeds apply as when working
with the crane; ➠ GMK 5100 Operating Instructions, part 2 Superstructure –
Crane operation.

• Switch the transfer case to off-the-road gear to move the truck crane;
➠ GMK 5100 Operating Instructions, part 1 Carrier – Driving the truck crane.
• Select a low gear on the transmission; ➠ GMK 5100 Operating Instruc-
tions, part 1 Carrier – Driving the truck crane.
• Drive at only a very low speed!
• The turning radius should be as large as possible when turning corners!
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3 - 78 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.10 Driving with rigged crane and lattice extension installed

• Steer the truck crane only when it is moving and avoid sudden steering
movements!
When the surface is uneven the truck crane must be raised with the outrig-
ger cylinders, horizontally aligned and then re-lowered;
➠ GMK 5100, part 2 Superstructure – Rigging work
and part 1 – Driving the truck crane.

Extending the The truck crane must be on outriggers before beginning work with the
outrigger crane; GMK 5100 Operating Instructions, part 2 Superstructure – Rigging work.

G
Risk of overturning!
The truck crane must be raised until no wheels touch the ground!

4 9
93
00
51
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Operating instructions for lattice extension 2 084 770 en 3 - 79

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.11 Malfunction when working with lattice extension!

H
3.11 Malfunction when working with lattice extension!

The information in the following table applies to malfunctions during

operation with the 11/18 m lattice exension as well as to operation with
the 26/34 m boom extension.

Malfunction Cause Action

The lifting limit switch does The lifting limit switch is not Switch on the lifting limit
not function connected switch; ➠ Lifting limit switch
on the lattice extension, p. 3-58.
No electrical connection Establish electrical
between boom head and connection; ➠ Electrical
lattice extension or between connection on the lattice
11 m section and 7 m section extension, p. 3-55.

9
Lifting limit switch on main Override lifting limit switch on
boom head not overridden the main boom head;
4 ➠ p. 3-58.
93
When operating with an 18 m Insert short-circuit plug;
lattice extension or boom ➠ p. 3-57.
extension the short-circuit
00

plug is not inserted on the

head of the 12.5 m section.
Main boom cannot be tele- Main boom is raised to an Raise main boom to required
51

scoped when lattice extensi- angle at which telescoping is angle;

on or boom extension is rig- not permitted ➠ Telescoping with rigged lattice
ged extension, p. 3-65.

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3 - 80 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Two-stage swing-away lattice extension (additional equipment)
3.12 Maintenance work

3.12 Maintenance work

3.12.1 Modules requiring protection during cleaning work

4 9
93

Provide protection for the following electrical parts during cleaning work:
00

– the control box on the fixed part of the 11 m section (1) and

H
51

– the control box at the front of the 7 m section (2)

Also observe all the instructions contained in the chapter titled Cleaning
work of the Maintenance Manual for the GMK 5100.
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Operating instructions for lattice extension 2 084 770 en 3 - 81

GMK 5100
Two-stage swing-away lattice extension (additional equipment)
3.12 Maintenance work

3.12.2 Maintenance work M1, monthly

H For lubricating the pins and support rollers, use the same grease as stated
in the Maintenance Manual for attach pins and socket pins; ➠ GMK 5100
Maintenance Manual, Overview of maintenance work – Maintenance plan M1.

Pins Lubricate all attach, securing and retaining pins. These are

– the pins for the pin connection on the lattice extension

– the securing pins on the deflection sheave and those for adjusting the
angle
– the retaining pins used for fastening the lattice extension sections for
transport.

H 9
The maintenance interval applies to average operation. Also lubricate the
pins after high-pressure cleaning and generally at an interval that will pre-
vent them getting dry. 4
93
00

Support rollers There are two support rollers on the lattice extension that need to be lubri-
cated.
51

The two support rollers (1) and (2) are on the

bottom of the 11 m section, at the height of
the run-up rail.

• Clean the lubricating nipples and insert

grease into the lubricating nipple with a
grease gun.
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3 - 82 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.1 Identification and slinging points

4 Boom extension (additional equipment)

4.1 Identification and slinging points

4.1.1 Identification

The boom extension consists of the 18 m two-stage swing-away lattice

extension and two boom extension sections. The boom extension is de-
signed for the truck crane it was delivered with. The parts belonging to
the truck crane have the same serial number as the truck crane.

The following parts are labelled with the serial number:

9
– all parts of the 18 m two-stage swing-away lattice extension; ➠ p. 3-1
4
– both sections of the boom extension (8 m sections).
93

S
Operate the truck crane only with those sections of the boom extension
which have the same serial number as the crane.
00

The SLI is only set for this boom extension.

This prevents malfunctions and damage.
51

H For technical reasons a truck crane may only be set with one boom
extension.

If you wish to use the boom extension on several GROVE truck cranes, the
parts of the boom extension must be adjusted for these cranes and label-
led with all of the respective serial numbers.

S
Have the adjustment of the boom extension carried out only by your local
GROVE Product Support!
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Operating instructions for lattice extension 2 084 770 en 4-1
GMK 5100
Boom extension (additional equipment)
4.1 Identification and slinging points

Serial numbers on the 8 m sections

On the 8 m sections the serial number (1) is
at the front on a sheet.

4 9
4.1.2 Slinging points
93

G
This section shows the slinging points on the 8 m sections.
Attach the sections on these slinging points only. They will then automat-
00

ically have the correct centre of gravity. Only use lifting gear with suffi-
cient load bearing capacity; ➠ Transport dimensions and weights, p. 2-1.
51

The 8 m sections have two slinging

points (1) (each slightly offset on each side).

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4-2 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.2 Assembly of boom extensions

4.2 Assembly of boom extensions

26 m boom extension
(85 ft boom extension)

8 m section 11 m section 7 m section

(26 ft section) (36 ft section) (23 ft section)

4 9
93
34 m boom extension
00

(112 ft boom extension)

51

8 m section 8 m section 11 m section 7 m section

(26 ft section) (26 ft section) (36 ft section) (23 ft section)

H The lengths of 26 m and 34 m respectively equal the distance between

the centre of the locking pin (on the main boom head) and the front edge
of the head sheave.
The designations 11 m section, 7 m section and 8 m section have been
adapted to these lengths. The total lengths of the individual sections are
greater; ➠ Transport dimensions and weights, p. 2-1.
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Operating instructions for lattice extension 2 084 770 en 4-3

GMK 5100
Boom extension (additional equipment)
4.2 Assembly of boom extensions

4 9
93

Blank page
00
51

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4-4 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.3 Check lists for rigging work

4.3 Check lists for rigging work

4.3.1 CHECKLIST: Installing the 26 m/34 m boom extension

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Requirements
– The truck crane is on outriggers or the main boom is placed on the
boom support.
– An auxiliary crane must be ready.

1. Prepare the truck crane for unrigging; ➠ Preparing the truck crane for rig-

9
ging, p. 3-27.

4
2. If the lattice extension is folded up at the side of the main boom, re-
move the lattice extension; ➠ CHECKLIST: Removing two-stage swing-
93
away lattice extension, p. 3-7.
00

3. Check the transport condition of the two-stage swing-away lattice

extension;
➠ Checking transport condition with removed lattice extension, p. 3-31.
51

4. Installing 8 m sections in front of the main boom:

For 26 m boom extension an 8 m section
For 34 m boom extension both 8 m sections
➠ Slinging point, p. 4-2.
➠ Installing/removing 8 m sections, p. 4-11.

5. Attach folded two-stage swing-away lattice extension in front of

8 m section; ➠ Installing/removing two-stage swing-away lattice extension
for boom extension, p. 4-12.
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Operating instructions for lattice extension 2 084 770 en 4-5
GMK 5100
Boom extension (additional equipment)
4.3 Check lists for rigging work

6. Attach guide rope to the head of the 7 m section.

7. Release connection between 7 m section and 11 m section;

➠ Connections in the middle area, p. 3-35.

8. Swivel the 7 m section in front of the 11 m section;

➠ Swivelling the 7 m section in front of the 11 m section, p. 3-47.

4 9
93
9. Fasten 7 m section with pin on left-hand side in front of 11 m section;
➠ Pin connections on the lattice extension, p. 3-42.
00
51

10. Establish electrical connections; ➠ Electrical connection on the boom

extension, p. 4-13.

11. Fold out deflection sheaves on all sections;

➠ Folding deflection sheaves on 11 m section in/out, p. 3-51
➠ Folding deflection sheaves on 8 m section in/out, p. 4-15.
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4-6 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.3 Check lists for rigging work

12. Place hoist cable over all the deflection sheaves and the head sheave
of the 7 m section; ➠ Positioning/removing hoist cable, p. 4-16.

13. Adjust angle if necessary; ➠ Adjusting angle on the lattice extension,

p. 3-48.

14. Move anemometer (additional equipment) from the head of the main
boom to the head of the 7 m section; ➠ Anemometer on lattice extension
– 18 m two-stage swing-away lattice extension, p. 3-60.

4 9
93
15. Move lifting limit switch from the head of the main boom to the head
of the 7 m section; ➠ Lifting limit switch on the lattice extension, p. 3-58.
00
51

16. Reeve the hoist cable on the hook block; ➠ Positioning/removing the
hoist cable, p. 3-54.

17. Attach lifting limit switch weight and guide hoist cable through the
weight; ➠ GMK 5100 Operating Instructions, part 2 Superstructure –
Crane operation.
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Operating instructions for lattice extension 2 084 770 en 4-7
GMK 5100
Boom extension (additional equipment)
4.3 Check lists for rigging work

18. Enter SLI code according toLifting capacity table for the actual rigging
00== mode of the truck crane with the 26 m or 34 m boom extension,
Setting the rigging mode ➠ GMK 5100 Operating Instructions, part 2 Super-
structure – Crane operation.

Further working steps for raising the boom; ➠ p. 3-63.

Telescoping with rigged boom extension; ➠ p. 3-65.

4.3.2 CHECKLIST: Removing the 26 m/34 m boom extension

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Requirements

9
– The truck crane is on outriggers or the main boom is placed on the
boom support. 4
93
– An auxiliary crane must be ready.
1. Prepare the truck crane for unrigging; ➠ Preparing the truck crane for rig-
ging, p. 3-27.
00

2. Fully retract and set down main boom.

51

3. Enter the SLI code according to the Lifting capacity table for the actual
00== rigging mode of the truck crane when the extension boom is rigged,
Setting the rigging mode ➠ GMK 5100 Operating Instructions, part 2 Super-
structure – Crane operation.

4. Remove lifting limit switch weight and move lifting limit switch from
the head of the 7 m section to the head of the main boom; ➠ Lifting li-
mit switch on the lattice extension, p. 3-58.
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4-8 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.3 Check lists for rigging work

5. Reeve out hoist cable from the hook block; ➠ Positioning/removing the
hoist cable, p. 3-52.

6. Remove anemometer (additional equipment); ➠ Anemometer on the lat-

tice extension, p. 3-60.

7. Detach electrical connections; ➠ Electrical connection on the boom exten-

sion, p. 4-13.

4 9
93
8. Adjust angle if necessary to 0°; ➠ Adjust angle on the lattice extension,
00

p. 3-48.
51

9. Remove hoist cable and fold in deflection sheaves on all parts of the
boom extension; ➠ Positioning/removing hoist cable, p. 4-16.
➠ Folding deflection sheaves on 11 m section in/out, p. 3-51.
➠ Folding deflection sheaves on 8 m section in/out, p. 4-15.

10. Reel hoist cable up to the main boom head.

08.05.2003

s
Operating instructions for lattice extension 2 084 770 en 4-9
GMK 5100
Boom extension (additional equipment)
4.3 Check lists for rigging work

11. Remove the locking pins on the left-hand side between 7 m section
and 11 m section;
➠ Pin connections on the lattice extension, p. 3-42.

12. Swivel the 7 m section onto the 11 m section side until the connection
between the two sections engages;
➠ Swivelling the lattice extension during rigging, p. 3-47.
➠ Connections in the middle area, p. 3-35.

13. Establish connection between 7 m section and 11 m section;

➠ Connections in the middle area, p. 3-35.

4 9
93
00

14. Remove folded two-stage swing-away lattice extension from 8 m sec-

tion; ➠ Installing/removing two-stage swing-away lattice extension for boom
extension, p. 4-12.
51

15. Remove 8 m sections from the main boom:

For 26 m boom extension an 8 m section
For 34 m boom extension both 8 m sections
➠ Slinging points on 8 m section, p. 4-2.
➠ Installing/removing 8 m sections, p. 4-11.
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4 - 10 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.4 Description of rigging work

4.4 Description of rigging work

4.4.1 Installing/disassembling 8 m sections

– In order to rig the 26 m boom extension you must install the 8 m secti-
on with support roller in front of the main boom head.
– To rig the 34 m boom extension you must also mount the 8 m section
without support roller in front of the 8 m section with support roller.

H An auxiliary crane must be used to install and remove the 8 m sections.

9
The securing pins (1) for the connection are
in the holders on the foot of the 8 m sections
4 and are secured with retaining pins.
93
Installing 8 m sections
• Sling the 8 m section with support roller
00

on an auxiliary crane and lift it in front of

the main boom head so that the bearing
points (2) and (3) align on both sides.
51

• Insert the securing pins on both sides into

the bearing points (2) and (3).
• Secure all pins with retaining pins.
• For the 34 m boom extension, install the
second 8 m section in the same way as the
first 8 m section.

Removing 8 m sections
• Sling the 8 m section on an auxiliary crane and lift it until the weight
has been taken off the bearing points (2) and (3).
• Release the pins and knock them out of the bearing points (2) and (3) on
both sides.
• Insert the pins into the holders on the foot of the 8 m sections and se-
08.05.2003

cure them with retaining pins.

Operating instructions for lattice extension 2 084 770 en 4 - 11

GMK 5100
Boom extension (additional equipment)
4.4 Description of rigging work

4.4.2 Installing/removing two-stage swing-away lattice extension

for boom extension

This section describes the installation and removal of the folded two-sta-
ge swing-away lattice extension.
You can also install the two-stage swing-away lattice extension which has
been folded in front of the other in front of an 8 m section (e.g. when you
are changing directly from the 18 m two-stage swing-away lattice exten-
sion to a boom extension).

H An auxiliary crane must be used to install and remove the two-stage

swing-away lattice extension.

The securing pins (1) for the connection are

in the holders on the foot of the 11 m sec-

9
tions and are secured with retaining pins.

4
Installation
93
• Sling the two-stage swing-away lattice
extension onto an auxiliary crane;
➠ Centre of gravity positions for slinging,
00

p. 3-4.
• Lift the two-stage swing-away lattice exten-
51

sion in front of the 8 m section so that the

bearing points (2) and (3) align on both
sides.
• Insert the securing pins on both sides into
the bearing points (2) and (3).
• Secure all pins with retaining pins.

Removing
• Sling the two-stage swing-away lattice extension onto an auxiliary cra-
ne; ➠ Centre of gravity positions for slinging, p. 3-4.
• Lift the two-stage swing-away lattice extension until the load has been
relieved from the bearing points.
• Release the pins and knock them out of the bearing points (2) and (3) on
both sides.
08.05.2003

• Insert the pins into the holders on the 11 m section and secure them
with retaining pins.

4 - 12 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.4 Description of rigging work

4.4.3 Electrical connection on the boom extension

This section describes the electrical connections on the 8 m sections.

For establishing electrical connection on the two-stage swing-away lattice
extension; ➠ Electrical connection on the lattice extension, p. 3-55.

Connections on
the 8 m sections
At the rear of the 8 m sections there is a
cable with a plug (3).
You can connect the cable to the main boom
head or a second 8 m section.

For transportation the cable is wound

around the holders (1) and the plug is inser-
ted in the dummy socket (2).

4 9
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00
51

At the front of the 8 m sections there is a

plug socket (1).
Here you can connect the cable of the 11 m
section or a second 8 m section.
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Operating instructions for lattice extension 2 084 770 en 4 - 13
GMK 5100
Boom extension (additional equipment)
4.4 Description of rigging work

Establishing For the 26 m boom extension

electrical
• Connect the cable of the 8 m section to the socket on the main boom
connections
head.
• Connect the cable of the 11 m section on the socket at the front of the
8 m section.

For the 34 m boom extension

• Connect the cable of the first 8 m section to the socket on the main
boom head.
• Connect the cable of the second 8 m section to the socket at the front of
the first 8 m section.
• Connect the cable of the 11 m section on the socket at the front of the
second 8 m section.

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51

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4 - 14 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.4 Description of rigging work

4.4.4 Folding out/in the deflection sheaves on the 8 m sections

This section describes only the folding in and out of the deflection sheave
on the 8 m section. To fold the deflection sheaves in and out on the
11 m section ➠ Folding out/in deflection sheaves on the 11 m section, p. 3-51.

If you intend to work with the boom extension you need to fold out the
deflection sheaves on the rear 8 m sections.
Fold the deflection sheave in for transportation.

Folding out deflection sheave

• Hold the deflection sheave by the strut (1)
and remove the pin from the bore (3).
• Fold the deflection sheave up and secure it
by inserting the pin into the bore (2).
• Secure the pin with a retaining pin.

4 9
93
00
51

Folding in deflection sheave

• Hold the deflection sheave by the strut (1)
and remove the pin from the bore (2).
• Fold the deflection sheave down and insert
the pin in the bore (3).
• Secure the pin with a retaining pin.
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Operating instructions for lattice extension 2 084 770 en 4 - 15

GMK 5100
Boom extension (additional equipment)
4.4 Description of rigging work

4.4.5 Positioning/removing the hoist cable

G
Risk of accidents due to falling parts!
Always secure the hoist cable holding rollers and rods with retaining pins.
This prevents elements coming loose, falling down and injuring people.

When setting an When setting an angle of 20° or 40°, positioning and removing the hoist
angle of cable is done in two steps:
20° or 40°
For positioning:
– Begin by placing the hoist cable over the deflection sheaves in the 8 m
section and in the fixed part of the 11 m section and attach to the con-
nection eye at the front.

9
– After having set the angle, disconnect hoist cable from connection eye
and guide over the front deflection sheave in the 11 m section and over
the head sheave. 4
93
For removal:
00

– Begin by removing hoist cable from head sheave and front deflection
sheave in the 11 m section and fasten to connection eye.
51

– After having set the 0° angle, disconnect hoist cable from connection
eye and take it off the deflection sheaves in the fixed part of the 11 m
section and the 8 m section.

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4 - 16 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.4 Description of rigging work

26 m boom extension

34 m boom extension

9
• Remove the hoist cable holding rollers and rods (1).
4
• Guide the hoist cable via the deflection sheaves (5), (4), (3) and via the
93
head sheave (2) on the 7 m section for both boom extensions.
• Put all hoist cable holding rollers and rods back in place and secure
00

these with retaining pins.

• Attach the hook tackle. The hoist rope can only be reeved once;
➠ p. 3-54.
51
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Operating instructions for lattice extension 2 084 770 en 4 - 17

GMK 5100
Boom extension (additional equipment)
4.4 Description of rigging work

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93

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51

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4 - 18 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.5 Driving with a rigged crane if boom extension is rigged

4.5 Driving with a rigged crane if boom extension is rig-

ged
This section describes how you can move the truck crane with an installed
counterweight and rigged lattice extension or boom extension.

G
Risk of accidents!
It is forbidden to move the truck crane with a load on the hook.
Put the load down before you move the truck crane.
Secure the hook block so that it cannot swing.

G
Risk of overturning!
Before a rigged crane can be driven, the superstructure must be locked
and the slewing gear permanent brake must be engaged.

4 9
93
4.5.1 Driving route
00

The route must be a flat, even surface. The level adjustment system can-
not compensate for uneven surfaces. If the surface pressure of the tyres
exceeds the permissible load on the ground, the surface pressure must be
increased using packing made of durable material (e.g. wooden planks).
51

S
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ Operating instructions GMK 5100, Part 1 Crane base – Technical in-
formation for crane base.
Do not reduce the tyre pressure!
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Operating instructions for lattice extension 2 084 770 en 4 - 19
GMK 5100
Boom extension (additional equipment)
4.5 Driving with a rigged crane if boom extension is rigged

4.5.2 Position of the boom

The vehicle may only be moved if certain conditions are met. The boom
may have to be moved to a specified position, depending on the installed
counterweight.

S
Damage may occur to the axle lines!
Always move the boom to the prescribed position before you move the
rigged truck crane. The permitted load on the axle lines will be exceeded
if the boom is in a position which deviates from the prescribed position.

• Set the appropriate SLI code for the rigging mode on the safe load indi-
00== cator. The SLI codes can be found in the Lifting capacity table.

• Move the boom into the prescribed position. The prescribed boom po-
sition can be found in the following tables.

G 9
Risk of accidents if SLI is overridden!
4
Always set the SLI rigging code corresponding to the current rigging
93
mode when you derrick the main boom into the prescribed position. Do
not override the SLI; the prescribed positions in the following tables are
all within the areas permitted according to the Lifting capacity tables.
00

The truck crane safe load indicator does not function when the SLI is over-
ridden!
51

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4 - 20 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.5 Driving with a rigged crane if boom extension is rigged

26 m boom The following table only applies if the 26 m boom extension is rigged.
extension Tables applying if 34 m boom extension is rigged; ➠ p. 4-22.
Tables applying if two-stage swing-away lattice extension is rigged;
➠ p. 3-75.

H The axle loads specified in the following tables refer to a driving mode
with the basic unit and 8 t hook tackle reeved on the lattice extension,
hook blocks must be unreeved.

Counter Telescoping Main Main Axle load 2) Axle load 2)

weight telescope section boom boom in t x 1000 lbs
in t I/II/III/IV inclination position1)
in ° front rear front rear

11.0 0/0/0/0 20 front 12.0 13.0 26.5 28.7

9
0/0/0/0 80 rear 11.5 13.5 25.4 29.8
20.0 0.5/0.5/0/0
0/0/0/0
20
80
4
front
rear
14.0
14.5
14.5
13.5
30.9
32.0
32.0
29.8
93
24.0 0.5/0/0/0 20 front 13.5 17.5 29.8 38.6
0/0/0/0 80 rear 15.5 14.0 34.2 30.9
00

31.0 0.5/0.5/0.5/0 20 front 16.5 16.0 36.4 35.3

0/0/0/0 70 rear 16.0 16.5 35.3 36.4
51

1)
Boom position at rear = 0° position, boom over truck crane rear edge
Boom position at front = 180° position, boom over driver’s cab
2)
The indicated values apply to a 20° inclination of the lattice extension.
For other inclinations the values change slightly.
Axle load front: on the 1st, 2nd and 3rd axle line respectively
rear: on the 4th and 5th axle line respectively
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Operating instructions for lattice extension 2 084 770 en 4 - 21
GMK 5100
Boom extension (additional equipment)
4.5 Driving with a rigged crane if boom extension is rigged

34 m boom The following table only applies if the 34 m boom extension is rigged.
extension Tables applying if 26 m boom extension is rigged; ➠ p. 4-21.
Tables applying if two-stage swing-away lattice extension is rigged;
➠ p. 3-75.

H
Counter Telescoping
The axle loads specified in the following tables refer to a driving mode
with the basic unit and 8 t hook tackle reeved on the lattice extension,
hook blocks must be unreeved.

Main boom Main boom Axle load 2) Axle load 2)

weight telescope inclination position1) in t x 1000 lbs
in t section in °
I/II/III/IV front rear front rear

11.0 0/0/0/0 20 front 14.0 10.5 30.9 23.2

0/0/0/0 80 rear 11.0 15.0 24.3 33.1
20.0 0.5/0/0/0 20 front 16.0 11.5 35.3 25.4
0/0/0/0 80 rear 14.0 15.0 30.9 33.1

9
24.0 0.5/0/0/0 20 front 15.5 14.5 34.2 32.0
0/0/0/0 80 rear 4 15.0 15.0 33.1 33.1
93
31.0 0.5/0.5/0/0 20 front 17.0 15.5 37.5 34.2
0/0/0/0 80 rear 17.0 15.5 37.5 34.2
00

1)
Boom position at rear = 0° position, boom over truck crane rear edge
51

Boom position at front = 180° position, boom over driver’s cab

2)
The indicated values apply to a 20° inclination of the lattice extension.
For other inclinations the values change slightly.
Axle load front: on the 1st, 2nd and 3rd axle line respectively
rear: on the 4th and 5th axle line respectively

4.5.3 Driving the rigged crane

Locking the su- Before the truck crane is moved, the superstructure must be locked to the
perstructure and carrier; ➠ GMK 5100 Operating Instructions, part 2 Superstructure – Crane
engaging the operation.
slewing gear per-
manent brake

• Lock the superstructure; the indicator lamp Superstructure locked must illu-
08.05.2003

! minate.
• Apply the slewing gear permanent brake and switch off the Slewing func-
Y tion to prevent inadvertent operation.

4 - 22 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.5 Driving with a rigged crane if boom extension is rigged

To do this push down the Slewing gear permanent brake rocker switch.
The Slewing gear permanent brake applied indicator lamp lights up when
the

H
slewing gear permanent brake is applied.

If the crane engine stops the slewing gear permanent brake is automat-
ically applied.

Retracting the • Retract the outrigger cylinders until the wheels are just above the
outrigger ground.

G
Risk of overturning!
Make sure that the truck crane does not overturn when the outriggers are
being retracted!
Retract all the outrigger cylinders as uniformly as possible!

9
Switching over
the suspension
locking system 4
• Switch the suspension locking system off. To do this push up the Sus-
93
u pension locking system rocker switch. The Suspension locking system indica-
tor lamp must go out.
00

• Retract the outrigger cylinders until the truck crane is approximately at

on-the-road level.
• Switch the suspension locking system back on again. To do this push
51

u down the Suspension locking system rocker switch. The Suspension locking
system indicator lamp lights up when the suspension system is locked.
• Continue to retract the outrigger cylinders.

G
Risk of overturning!
To reduce the risk of the crane overturning do not raise the outrigger
pads more than 5 to 10 cm off the ground. Leave the outrigger beams
extended.

Switching on Before driving with the rigged crane you must switch on the separate
separate steering steering:

• Switch on the Level adjustment system key switch.

08.05.2003

C0018
s
Operating instructions for lattice extension 2 084 770 en 4 - 23
GMK 5100
Boom extension (additional equipment)
4.5 Driving with a rigged crane if boom extension is rigged

• Switch on separate steering by releasing the Separate steering rocker

b switch and pressing it down.

S
Damage may occur to steering linkage!
Before driving with the rigged crane always switch on separate steering
and steer the truck crane only when the vehicle is moving.
If separate steering is switched off or if you steer with the vehicle statio-
nary the steering linkage may become damaged.

Driving

S
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ GMK 5100 Operating Instructions, part 1 Carrier – Driving the truck

9
crane.
Do not reduce the tyre pressure!
4
H
93
The wind speed must be checked before the rigged truck crane is moved!
The same maximum permissible wind speeds apply as when working
00

with the crane; ➠ GMK 5100 Operating Instructions, part 2 Superstructure –

Crane operation.
51

• Select a low gear on the transmission; ➠ GMK 5100 Operating Instruc-

tions, part 1 Carrier – Driving the truck crane.
• Drive at only a very low speed!
• The turning radius should be as large as possible when turning corners!
• Steer the truck crane only when it is moving and avoid sudden steering
movements!
When the surface is uneven the truck crane must be raised with the outrig-
ger cylinders, horizontally aligned and then re-lowered;
➠ GMK 5100 Operating Instructions, part 2 Superstructure – Rigging work
and part 1 – Driving the truck crane.

Extending the The truck crane must be on outriggers before beginning work with the
outrigger crane; GMK 5100 Operating Instructions, part 2 Superstructure – Rigging work.
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4 - 24 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Boom extension (additional equipment)
4.6 Maintenance work

4.6 Maintenance work

4.6.1 Maintenance work M1, monthly

H For lubricating the pins, use the same grease as stated in the Maintenance
Manualfor attach pins and socket pins; ➠ GMK 5100 Maintenance Manual,
Overview of maintenance work – Maintenance plan M1.

• Lubricate all attach, securing and retaining pins.

H The maintenance interval applies to average operation. Also lubricate the

pins after high-pressure cleaning and generally at an interval that will pre-
vent them getting dry.

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51
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Operating instructions for lattice extension 2 084 770 en 4 - 25

GMK 5100
Boom extension (additional equipment)
4.6 Maintenance work

4 9
93

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00
51

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4 - 26 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Auxiliary single-sheave boom top (additional equipment)
5.1 Identification

5 Auxiliary single-sheave boom top (additional

equipment)

5.1 Identification
The auxiliary single-sheave boom top is designed for the truck crane it
was delivered with. It has the same serial number as the truck crane.

S
Operate the truck crane only with the auxiliary single-sheave boom top
that has the identical serial number.

9
If you wish to use the boom top on several GROVE truck cranes, it needs
4
to be adapted to the corresponding crane and marked with all the serial
numbers.
93

S
The auxiliary single-sheave boom top should only be adjusted by your
00

local GROVE Product Support!

51

The serial number (1) is found on the side of

the auxiliary single-sheave boom top.
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Operating instructions for lattice extension 2 084 770 en 5-1

GMK 5100
Auxiliary single-sheave boom top (additional equipment)
5.1 Identification

4 9
93

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00
51

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5-2 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Auxiliary single-sheave boom top (additional equipment)
5.2 Installing/removing auxiliary single-sheave boom top

5.2 Installing/removing auxiliary single-sheave boom top

G
Risk of accidents if the boom top should fall off!
During installation and removal, always use the proper materials with
sufficient load bearing capacities; ➠ Transport dimensions and weights,
p. 2-1.

5.2.1 Installing boom top

On the left side of the main boom head there is a holding device.
When installing, the auxiliary single-sheave boom top is connected to the
front bore holes (1) on the holding device.

4 9
93
• Loosen the retaining pin and remove the
pin (1) from the bearing point (2).
00

• Use an auxiliary crane to couple to the con-

nection eyes (3) on the auxiliary single-
51

sheave boom top and lift it to the left onto

3 the main boom head.
• Align the auxiliary single-sheave boom top
so that the bearing point (2) lines up to the
front bore holes in the holding device.
• Secure the boom top to the holding device
using a pin (1).
• Secure the pin with a retaining pin.

• Depending on the application, bring the auxiliary single-sheave boom

top into transport position or working position; ➠ Rigging the auxiliary
single-sheave boom top, p. 1-7.
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Operating instructions for lattice extension 2 084 770 en 5-3

GMK 5100
Auxiliary single-sheave boom top (additional equipment)
5.2 Installing/removing auxiliary single-sheave boom top

5.2.2 Removing the auxiliary single-sheave boom top

The boom top is mounted to a holding device on the left side of the main
boom head.
When removing, the locking pins are first taken out of the front bore holes
(1) in the holding device.

• Sling the auxiliary single-sheave boom top

to the connection eyes (3) using an auxilia-
ry crane.
• Take out the retaining pin and remove the
pin (1) from the bearing point (2) on the au-

9
xiliary single-sheave boom top.
• Lift the auxiliary single-sheave boom top
4
from the head of the main boom.
93
• Replace the pin (1) into the bearing point
on the boom top.
00

• Secure the pin with a retaining pin.

51

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5-4 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Auxiliary single-sheave boom top (additional equipment)
5.3 Rigging the auxiliary single-sheave boom top

5.3 Rigging the auxiliary single-sheave boom top

5.3.1 Rigging in transport position

On the left side of the main boom head there is a holding device.
In transport position, the boom top is connected to the rear bore holes (1)
on the holding device.

• Remove the retaining pins and take both

pins (1) out of the bearing points (2) at the
front of the main boom head.

9
• Insert both pins into the holders (3) and
secure them with retaining pins.
4 • Slew the auxiliary boom top to the side of
93
the main boom head.
00
51

• Remove the retaining pin and take the thin

pin (1) out of the holder (2).
• Secure the boom top to the bearing
point (3) using the pin.
• Secure the pin with a retaining pin.

The auxiliary single-sheave boom top is now

in transport position.
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Operating instructions for lattice extension 2 084 770 en 5-5

GMK 5100
Auxiliary single-sheave boom top (additional equipment)
5.3 Rigging the auxiliary single-sheave boom top

5.3.2 Rigging in working position

On the left side of the main boom head there is a holding device.
In working position, the auxiliary single-sheave boom top is attached to
the main boom head at both bore holes.

• Loosen the retaining pin and remove the

pin (1) from the bearing point (3).
• Insert both pins into the bearing points (2)
at the front of the main boom head and
secure them with retaining pins.

• Slew the auxiliary boom top to the side of

9
the main boom head.
4
93
00
51

• Remove the retaining pin and take out

both thick pins (1) from the holders (3).
• Insert both pins into the pivot points (2) at
the front of the main boom head and secure
them with retaining pins.

The auxiliary single-sheave boom top is now

in working position.
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5-6 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Auxiliary single-sheave boom top (additional equipment)
5.3 Rigging the auxiliary single-sheave boom top

5.3.3 Attaching and removing hoist cable

• Remove the cable holding rods (1) from

the head of the main boom and from the
auxiliary single-sheave boom top.
• When reeving, guide the hoist cable over
the left head sheave of the main boom.
• Insert the cable holding rod into the appro-
priate bore holes and secure them with the
corresponding retaining pins.
• Fasten the cable end clamp on the hook
tackle or the hook block.

9
Reverse the sequence of operations to remove the hoist cable before
4
slewing the auxiliary boom top into transport position.
93
00

5.3.4 Possible reeving methods on the auxiliary single-sheave

boom top
51

The hoist cable may only be simply reeved (single drop).

Hook tackle, max. load bearing capacity 8 t

Max. load bearing capacity with the GMK 5100:

for simple reeving 7 t (15,432 lbs)

1-sheave hook block, max. load bearing

capacity 20 t
08.05.2003

Max. load bearing capacity with the GMK 5100:

for simple reeving 7 t (15,432 lbs)

Operating instructions for lattice extension 2 084 770 en 5-7

GMK 5100
Auxiliary single-sheave boom top (additional equipment)
5.3 Rigging the auxiliary single-sheave boom top

5.3.5 Lifting limit switch and anemometer

In operation

• Pull the plug of the connecting cable from

the dummy socket (2).
• Unwind the connecting cable from the hol-
ders (3).
• Insert the plug of the connecting cable into
the socket (1) on the main boom head.
• Guide the hoist cable through the lifting
limit switch weight.
If, additionally, a hook block is reeved on the
main boom, connect the lifting limit switch
of the main hoist to the socket on the right
side of the main boom head;

9
➠ GMK 5100 Operating instructions, Part 2
Superstructure – rigging work.
4
93
00

During transport

• Insert the plug of the connecting cable into

51

the dummy socket (2).

• Wind the connecting cable onto the hol-
ders (3).
• Plug the short-circuit plug into the socket (1).

Anemometer • The anemometer is connected to the main boom head as it is for opera-
tion with the main boom; ➠ GMK 5100 Operating instructions, Part 2 Super-
08.05.2003

structure – rigging work.

5-8 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Auxiliary single-sheave boom top (additional equipment)
5.4 Turning loads with the auxiliary single-sheave boom top

5.4 Turning loads with the auxiliary single-sheave boom top

When turning loads, it is necessary to employ a two-hook operation. The
only type of two-hook operation technically possible and protected by the
SLI is described in this chapter using the turning of loads as an example.

G
Risk of accidents due to overloading!
Lifting a load with two hooks is permissible only if the following instruc-
tions and illustrations are observed!
If these instructions are not observed, accidents could occur due to indivi-
dual parts of the truck crane being overloaded! The SLI then no longer
provides protection.
Two-hook operation with the boom extension (additional equipment) is
not permitted!

G
Risk of accidents due to overloading!
The load must always be lifted with the weakest part first (auxiliary single-

9
sheave boom top).

4
H
93

Regarding position and function of required operating instruments;

00

➠ GMK 5100 Operating instructions, Part 2 – Description of the truck crane

(crane section).
51

Requirements The following description requires that:

– the main hoist cable is reeved on the main boom and
– the auxiliary hoist cable on the auxiliary single-sheave boom top is reeved.

G
Risk of accidents due to overloading!
The reeving on the main boom must be equal to or greater than that on
the auxiliary single-sheave boom top.
If this condition is not fulfilled, the main hoist cable and main hoisting
gear will become overloaded.
08.05.2003

s
Operating instructions for lattice extension 2 084 770 en 5-9
GMK 5100
Auxiliary single-sheave boom top (additional equipment)
5.4 Turning loads with the auxiliary single-sheave boom top

H
Setting SLI For two-hook operation, both hoists must be activated on the SLI.

It is advisable to enter the reevings for both hoists at the start. The values
are stored and called up directly when switching hoisting gears. This eli-
minates the need for input later during operation. Proceed as follows:

• Switch off both hoists.

Cü To do this, press down both rocker switches Auxiliary hoist shutdown and
Main hoist shutdown.
• Switch on the main hoist.
ü To do this, push up the rocker switch Main hoist shutdown.

Lamp I for the main hoist lights up from the Hoists indicator lamps.

4 9
93
• In the display Reeving , enter the quantity of reeved cable of the main
" n= hoist cable on the main boom.
00

Now the reeving for the main hoist is stored and you can switch to the
auxiliary hoist.
51

• Switch off both hoists.

Cü To do this, press down both rocker switches Auxiliary hoist shutdown and
Main hoist shutdown.
• Switch on the auxiliary hoist.
C To do this, push up the rocker switch Auxiliary hoist shutdown.
On the indicator lamps Hoists, lamp II is flashing for the auxiliary hoist.

• In the display Reeving, enter the quantity of reeved rope on the auxiliary
! n= hoist rope of the auxiliary single-sheave boom top.
Now the reeving for the auxiliary hoist is also stored and you can switch
08.05.2003

on the main hoist.

5 - 10 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Auxiliary single-sheave boom top (additional equipment)
5.4 Turning loads with the auxiliary single-sheave boom top

• Switch the main hoist on by pushing up the Main hoist shutdown rocker
ü switch.
• On the display lamps Hoists, lamp II is now lit for the auxiliary hoist and
lamp I is flashing for the main hoist.

• Set the SLI for crane operation with the auxiliary single-sheave boom
11=0 top, valid for the current rigging mode of the truck crane.
Now the SLI is set for two-hook operation, taking into account the reeving

H
for the auxiliary hoist and the lifting capacity table for the main boom.

The load measurement is taken using the pressure in the main boom’s
derricking cylinder. The loads detailed in the Lifting capacity table then

9
lessen with respect to the weight of both reeved hook blocks and the
weight of the auxiliary single-sheave boom top.
4
93
00

Turning a load To turn loads, proceed only in the manner described as follows.

S
Keep the acceleration force as low as possible during two-hook operation.
51

Therefore move the load at the lowest possible speed!

H As soon as the hoist cable on the main boom is pulled taut, the status dis-
play Actual load will exhibit slight variations. However, the differences are

H
on the safe side with regard to SLI deactivation.

With two-hook operation, the SLI code for the main boom remains acti-
vated during the entire hoist procedure.
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s
Operating instructions for lattice extension 2 084 770 en 5 - 11
GMK 5100
Auxiliary single-sheave boom top (additional equipment)
5.4 Turning loads with the auxiliary single-sheave boom top

C0985

9
• Lift the load completely off the ground with the auxiliary single-sheave
boom top.
4
• Only now should you attach the load to the hook block of the main
93
boom as well.
• Now lift the load with the hook block on the main boom until both sling-
00

ing points are at the same height.

51

C0984
08.05.2003

• Reel off hoist cable on the auxiliary single-sheave boom top until the
load is hanging exclusively from the hook block on the main boom.
Turning the load is thus completed.

5 - 12 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.1 Identification

6 Heavy load lattice extension

6.1 Identification
The heavy load lattice extension is matched to the truck crane with which
it was delivered. Heavy load lattice extension has the same serial number
as the truck crane.

S
Operate the truck crane only with the heavy load lattice extension that
has the identical serial number as the truck crane.

If you wish to use the lattice extension on several GROVE truck cranes,

9
the extension must be adjusted for these cranes and labelled with all of
4
the respective serial numbers.
93

S
Have the adjustment of the heavy load lattice extension carried out only
by GROVE Product Support at the respective location.
00
51

The serial number is located on the holding

device (1) and in the front on the heavy load
lattice extension (2).
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Operating instructions for lattice extension 2 084 770 en 6-1

GMK 5100
Heavy load lattice extension
6.1 Identification

4 9
93

Blank page
00
51

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6-2 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.2 Mount / remove heavy load lattice extension

6.2 Mount / remove heavy load lattice extension

G
Risk of accidents due to falling heavy load lattice extension.
During installation and removal, always use the proper materials with suf-
ficient load bearing capacite; ➠ Transport dimensions and weights; p. 2-1.

6.2.1 Installing the heavy load lattice extension

On the left side of the main boom head there is a holding device.
When installing, the heavy load lattice extension is connected at the front
bore holes (1) of the holding device.

4 9
• Release the retaining pin and remove the
93
pin (1) from the bearing point on the (2)
heavy load lattice extension.
00

• Use an auxiliary crane to couple the heavy

load lattice extension to the connection
eyes (3) and lift it to the left onto the main
51

boom head.
• Align the heavy load lattice extension so
that the bearing point (2) lines up to the
front bore holes in the holding device.
• Secure the heavy load lattice extension to
the holding device using a pin (1).
• Secure the pin with a retaining pin.

• Depending on the application, bring the heavy load lattice extension

into transport position or working position; ➠ Rigging heavy load lattice ex-
tension; p. 6-9.
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Operating instructions for lattice extension 2 084 770 en 6-3

GMK 5100
Heavy load lattice extension
6.2 Mount / remove heavy load lattice extension

6.2.2 Removing the heavy load lattice extension

When driving on public roads, the heavy load lattice extension must al-
ways be removed.

The heavy load lattice extension is mounted to a holding device on the

left side of the main boom head.
When removing, the locking pins are taken out of the front bore holes (1)
in the holding device.

• Attach the heavy load lattice extension

with the help of auxiliary crane to the con-
nection eyes (3).
• Release the retaining pin and remove the
pin (1) from the bearing point on the (2)
heavy load lattice extension.
• Lift the heavy load lattice extension from

9
the head of the main boom.
4
• Reinsert the pin (1) in the bearing point on
93
the heavy load lattice extension.
• Secure the pin with a retaining pin.
00

• Set heavy load lattice extension on a sepa-

rate vehicle; ➠ Transport on separate vehicle,
p. 6-19.
51

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6-4 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.3 Rigging work check lists

6.3 Rigging work check lists

6.3.1 CHECK LIST: Changing the heavy load lattice extension

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Comply with the warning and safety information given there.

Prerequisites:
– The heavy load lattice extension is bolted to the side of the main boom.
– The counterweight is rigged for operation with the heavy load lattice ex-
tension.

9
1. Swivel the heavy load lattice extension in front of the main boom
head; ➠ p. 6-10.
4
93
00

2. Fold out holding rods and pin them on the main boom head;
➠ p. 6-12.
51

3. Swivel the heavy load lattice extension into working postion;

➠ p. 6-13.

4. Establish electrical connection between lifting limit switch and main

boom; ➠ p. 6-13.
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s
Operating instructions for lattice extension 2 084 770 en 6-5
GMK 5100
Heavy load lattice extension
6.3 Rigging work check lists

5. Lay the auxiliary hoist rope and reeve it on hook block; ➠ Possible ree-
vings on the heavy load lattice extension, p. 6-16.

6. Mount lifting limit switch weight; ➠ GMK 5100 Operating instructions,

Part 2, Superstructure – Crane operation.

7. SLI-code in the lifting capacity table for the actual rigging mode of the
truck crane with the heavy load lattice extension; ➠ GMK 5100 Opera-
00== ting instructions, Part 2, Superstructure – Crane operation.

4 9
93
00
51

08.08.2003

6-6 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.3 Rigging work check lists

6.3.2 CHECK LIST: Unrigging heavy load lattice extension

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Comply with the warning and safety information given there!

Requirement:
– SLI code according to the Lifting capacity table is set.

1. Fully retract and set down main boom.

2. Remove lifting limit switch weight; ➠ GMK 5100 Operating instructions,

9
Part 2, Superstructure – Crane operation.
4
93
00

3. Unreeve and reel up the hoist rope on the hook block; ➠ GMK 5100
51

Operating instructions, Part 2, Superstructure – Crane operation.

4. Detach the electrical connection between lifting limit switch and main
boom; ➠ p. 6-13.

5. Lower the heavy load lattice extension in transport position;

➠ p. 6-13.
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s
Operating instructions for lattice extension 2 084 770 en 6-7
GMK 5100
Heavy load lattice extension
6.3 Rigging work check lists

6. Fold out holding rods and pin them on the heavy load lattice extensi-
on; ➠ p. 6-12.

7. Swivel the heavy load lattice extension on the main boom head;
➠ p. 6-9.

4 9
93
00
51

08.08.2003

6-8 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

6.4 Rigging / unrigging the heavy load lattice extension

6.4.1 Rigging the heavy load lattice extension

Prerequisites The following requirements must be met before rigging of the heavy load
lattice extension:

– The heavy load lattice extension has been swivelled onto the main
boom,
– All telescopic parts are fully retracted,
– Turn superstructure forward and the main boom is in the support,
or
– The truck crane is supported with the outrigger span of at least
7.80 m x 5.10 m and the superstructure is slewed in random position.

4 9
93
00
51
08.08.2003

s
Operating instructions for lattice extension 2 084 770 en 6-9
GMK 5100
Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

Swiveling the For transporting on the construction site, the heavy load lattice extension
lattice extension is slewed sideways on the main boom and is secured with a pin (2) with
in front of main the retaining pin.
boom
• Remove the retaining pin and pull the pin
out of the bore (2).
• Slew the heavy load lattice extension
around the swievel pins (1) in front of the
main boom.

4 9
93
The bore holes in the heavy load lattice ex-
tension line up with the bore holes in the
main boom.
00

• Remove the pin (1) from the holder (3) and

insert them through the aligning bore ho-
51

les. Thereby, handles on the pins must

point forwards.
• Secure the pins (1) using retaining pins.
• Insert the locking pin (2) in the bore holes
and secure it with a locking plug.

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6 - 10 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

Slew the heavy

load lattice exten-
sion onto the
main boom
• Release the retaining pins from the pins (4)
and remove them from the bores (1).
• Insert the pin into the holders on the heavy
load lattice extension.
• Remove the retaining pin and pull the lok-
king pin out of the bore (3).
• Slew the heavy load lattice extension
around the swievel pins (2) sideways to
the main boom.

4 9
The bore holes in the heavy load lattice ex-
93
tension line up with the bore holes in the
main boom.
00

• Insert the locking pin (1) into the aligning

bores.
• Secure all pins with retaining pins.
51
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Operating instructions for lattice extension 2 084 770 en 6 - 11

GMK 5100
Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

Folding and unfol- The holding rods (2) are folded in transport position and are fastened on
ding of holding the heavy load lattice extension using both short pins (1) with retaining
rods pins.

• Remove the retaining pins and remove

short bolts (1) to the right and left from the
fork elements (3) and the holding device
on the heavy load lattice extension.
• Fold out both the holding rods (2) on the
top on the main boom head.

4 9
• Insert both the fork elements (2) of the hol-
93
ding rods on the holding devices (3) on the
main boom.
• Insert both the pins (1) through the fork ele-
00

ments (2) and holding devices (3) and secu-

re them with retaining pins.
51

08.08.2003

6 - 12 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

Swivel the heavy The heavy load lattice extension is retained by the pins (2) with retaining
load lattice exten- pin in transport position.
sion into working
position The pin (2) connects the bores (1) in the holding device and the heavy
load lattice extension.

• Remove the retaining pin from the pin (2).

The gas pressure spring (3) works against
the dead weight of the heavy load lattice ex-
tension, so that it can be lifted with one
hand.

• Lift the heavy load lattice extension some-

what, so that the pin (2) is unloaded.
• Withdraw pin (2) from the bores (1).
The heavy load lattice extension lowers itself
in the working position.

9
• Reinsert the pin (2) in the bores (1) in the
4 heavy load lattice extension and lock it
into place using a retaining pin.
93
The heavy load lattice extension is in wor-
king position.
00

Swivel the heavy

load lattice exten-
sion into trans-
51

port postion
• Remove the retaining pin from the pin (2)
and pull it out from the bores of heavy
load lattice extension.
• Raise the heavy load lattice extension until
the bores (1) in the heavy load lattice ex-
tension and holding device align.
The gas pressure spring (3) works against the
dead weight of the heavy load lattice extensi-
on, so that it can be lifted with one hand.

• Insert the pin (2) through the bores (1) of

the heavy load lattice extension and hol-
ding device. Secure the pin with a retai-
ning pin.
Now the heavy load lattice extension is in
08.08.2003

transport position.

s
Operating instructions for lattice extension 2 084 770 en 6 - 13
GMK 5100
Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

Position and re-

move the hoist
rope

• Remove the rope holding rods (1) on the

main boom and the heavy load lattice ex-
tension.
• Guide the hoist rope of the auxiliary hoist
unit with the rope end clamp over the left
head sheave (2) on the main boom in the
heavy load lattice extension (3) and out
through the opening (4) of the heavy load
lattice extension.
• Guide the hoist rope over the head sheave
(5) of the heavy load lattice extension.
• Reinsert all rope holding rods (1) and lock
them into place using retaining pins.

9
The double reeved hoist rope is attached at fi-
xing point (6); ➠ GMK 5100 Operating instructi-
4
ons, Part 2, Superstructure – Rigging work.
93
Reverse the sequence of operations to remove the hoist cable before sle-
00

wing the heavy load lattice extension into transport position.

51

SLI set • Set the rigging code on the SLI according to the Load capacity chart for
operating with the heavy load lattice extension with reference to the cur-
rent rigging mode; ➠ GMK 5100 Operating instructions, Part 2, Superstruc-
ture – Crane operation.

08.08.2003

6 - 14 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

Possible reeving The hoist rope of the auxiliary hoist should be reeved only 1-fall or 2-fall
methods on the on the heavy load lattice extension.
heavy load lattice
extension

Hook tackle, maximum lifting capacity 8 t 1-fall

maximum lifting capacity with GMK 5100:

for reeving 1-fall 7 t (15,432 lbs)

1-sheave hook tackle, maximum lifting capacity 1-fall 2-fall

9
20 t

maximum lifting capacity with GMK 5100:

4
93
for reeving 1-fall 7 t (15,432 lbs)
for reeving 2-fall 14 t (30,864 lbs)
00
51
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Operating instructions for lattice extension 2 084 770 en 6 - 15

GMK 5100
Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

Lifting limit
switch and ane-
mometer
Lifting limit switch for operation
• Pull the plug of the connecting cable from
the dummy socket (2).
• Unwind the connecting cable from the hol-
ders (3).
• Insert the plug of the connecting cable into
the socket (1) on the main boom head.
• Guide the hoist rope through the lifting li-
mit switch weight; ➠ GMK 5100 Operating
instructions, Part 2, Superstructure – Rigging
work.
If, additionally, a hook block is to be reeved
on the main boom, connect the lifting limit
switch of the main hoist to the socket on the

9
right side of the main boom head;
➠ GMK 5100 Operating instructions, Part 2,
4
Superstructure – Rigging work.
93
Lifting limit switch for transport
00

• Insert the plug of the connecting cable into

the dummy socket (2).
• Wind the connecting cable onto the hol-
51

ders (3).
• Insert the short-circuit plug into the sok-
ket (1).

Anemometer • The anemometer is connected to the main boom head as it is for opera-
tion with the main boom; ➠ GMGMK 5100 Operating instructions, Part 2,
Superstructure – Rigging work.
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6 - 16 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

6.4.2 Removing the heavy load lattice extension

Prerequisites The heavy load lattice extension is rigged, otherwise the same prereq-
uisites apply as for rigging, ➠ p. 6-9.

Sequence during Unrigging is done in the reverse order of rigging. Listed below are the in-
unrigging vidual steps for unrigging. Detailed information to be extracted from the
relevant places in the section rigging; ➠ p. 6-9.

– Remove the lifting limit switch weight, unreeve hook block and reel up
the hoist rope,
– Disconnect electrical connection,
– Pin the holding rods on the single-sheave boom top,
– Fold the holding rods and pin them with the heavy load lattice
extension,

9
– Lower the heavy load lattice extension in transport position and pin,

4
– Release the pins on the holding device, slew the heavy load lattice ex-
tension sideways on the main boom and secure with pins.
93
00

Transportation For driving on open roads, the heavy load lattice extension on the main
on a separate boom must be removed and set on a separate vehicle.
51

vehicle

G
Risk of injury!
Sling the lattice extension only on the designated slinging points and use
only lifting gear with sufficient load bearing capacity.
This prevents the lattice extension from falling and injuring people while
loading.

For transport, set the lattice extension down such that it will not be
damaged.

• Additionally, always secure the lattice extension on the separate vehicle

with belts to prevent slipping and overturning.
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Operating instructions for lattice extension 2 084 770 en 6 - 17

GMK 5100
Heavy load lattice extension
6.4 Rigging / unrigging the heavy load lattice extension

4 9
93

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00
51

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6 - 18 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.5 Operation with the heavy load lattice extension

H
6.5 Operation with the heavy load lattice extension

If a heavy load lattice extension is reeved during operation with the main
boom, the loads given in the Lifting capacity tables decrease. The values
which have to be taken off the loads are given in the Lifting capacity tables

H
in their own table.

The hoisting, lowering, slewing, derricking and telescoping movements

are done in the same way as when operating with the main boom.

SLI-shutdown The SLI monitors operation when working with the heavy load lattice ex-
tension.
SLI shutdowns can occur during lattice extension operation for the same
reasons as with main boom operation; ➠ GMK 5100 Operating instructions,
Part 2, Superstructure – Crane operation.

4 9
Procedure if the Strong winds can overstrain the truck crane. It is therefore important to
permissible wind pay close attention to the instructions in influence of wind on crane work,
93
speed is exceeded ➠ GMK 5100 Operating instructions, Part 2, Superstructure – Crane operation.
Procedure if the permissible wind speed is exceeded while carrying out
00

crane work with the heavy load lattice extension

Wind speed less than 20 m/s Wind speed greater than 20 m/s
51

• Set down the load. • Set down the load.

• Slew the superstructure so that • Fully retract the main boom.

the main boom creates as little
wind resistance as possible. • Place the main boom with heavy
load lattice extension in the
boom support.
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Operating instructions for lattice extension 2 084 770 en 6 - 19

GMK 5100
Heavy load lattice extension
6.5 Operation with the heavy load lattice extension

6.5.1 Telescoping with rigged heavy load lattice extension

S
The main boom may become overloaded!
While you are telescoping the main boom with the rigged heavy load latti-
ce extension, you may not simultaneously slew the superstructure.
This prevents the main boom being subjected to additional side forces
and increased vibration and becoming overloaded.

Telescoping with a load is released by the SLI only for loads which are be-
low the values in the rigging programs.
• Set down the load.
• Derrick in the main boom by the appropriate angle according to the rig-
ging program (➠ Rigging program in the lifting capacity table).
Telescope the main boom by the required length, taking into account the
hook block; lower or raise it using the hoist.
Do not actuate the slewing gear when telescoping.

4 9
93
6.5.2 Raising and placing the main boom with rigged heavy load
lattice extension

H
00

To raise and set down the main boom with a rigged lattice extension, the
main boom must be fully retracted because the SLI then automatically
51

switches to the rigging program.

To raise and set down, the following requirements must be met:

– The SLI code for the actual rigging mode is set on the SLI with the rig-
ged heavy load lattice extension; ➠ Operating instructions, setting the rig-
00== ging code.
– The current reeving of the hoist cable on the lattice extension is entered.
1 – Apart from the hook block there is no load on the lattice extension.
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6 - 20 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.6 Turning loads with the heavy load lattice extension

6.6 Turning loads with the heavy load lattice extension

When turning loads it is necessary to employ a two-hook operation. The
only type of two-hook operation technically possible and protected by the
SLI is described in this chapter using the turning of loads as an example.

G
Risk of accidents due to overloading!
Lifting a load with two hooks is permissible only if the following instructi-
ons and illustrations are observed.
If these instructions are not observed, accidents could occur due to indivi-
dual parts of the truck crane being overloaded. The SLI then no longer
provides protection.
Two-hook operation with the boom extension (additional equipment) is
not permitted.

G
Risk of accidents due to overloading!
The load must always be lifted completely with the weakest part first (hea-

9
vy load lattice extension).

4
H
93

For the position and functions of the needed operating elements;

00

➠ GMK 5100 Operating instructions, Part 2, Description of the truck crane – Cra-
ne section.
51

Prerequisites The following description requires that:

– the main hoist cable is reeved on the main boom and
– the auxiliary hoist rope on the heavy load lattice extension is reeved.

G
Risk of accidents due to overloading!
The reeving on the main boom must be equal to or greater than that on
the heavy load lattice extension!
If this condition is not fulfilled, the main hoist rope and main hoisting
gear will become overloaded.
08.08.2003

s
Operating instructions for lattice extension 2 084 770 en 6 - 21
GMK 5100
Heavy load lattice extension
6.6 Turning loads with the heavy load lattice extension

H
Setting SLI For two-hook operation, both hoists must be activated on the SLI.

It is advisable to enter the reevings for both hoists at the start. The values
are stored and called up directly when switching hoisting gears. This eli-
minates the need for input later during operation. Proceed as follows:

• Switch off both hoists.

Cü To do this, press down both rocker switches Auxiliary hoist shutdown
and Main hoist shutdown.
• Switch on the main hoist.
ü To do this, push up the rocker switch Main hoist shutdown.
Lamp I for the main hoist lights up in the Hoists indicator lamps.

9
• In the display Reeving, enter the quantity of reeved rope of the main
§ hoist rope on the main boom. 4
93
Now the reeving for the main hoist is stored and you can switch to the au-
xiliary hoist.
00

• Switch off both hoists.

Cü To do this, press down both rocker switches Auxiliary hoist shutdown
51

and Main hoist shutdown.

• Switch on the auxiliary hoist.
C To do this, push up the rocker switch Auxiliary hoist shutdown.
At the Hoists indicator lamps, lamp II flashes for the auxiliary hoist.

• In the display Reeving, enter the number of reeved ropes on the auxiliary
hoist rope of the auxiliary hoist rope on the heavy load lattice extensi-
on.
Now the reeving for the auxiliary hoist is also stored and you can switch
on the main hoist.
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6 - 22 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Heavy load lattice extension
6.6 Turning loads with the heavy load lattice extension

• Switch the main hoist on by pushing up the Main hoist shutdown rocker
ü switch.
• On the Hoists indicator lamps, lamp II is now lit for the auxiliary hoist
and lamp I flashes for the main hoist.

• Set the SLI code for crane operation with the heavy load lattice extensi-
11=0 on, valid for the current rigging mode of the truck crane.
Now the SLI is set for two-hook operation, taking into account the reeving

H
for the auxiliary hoist and the lifting capacity table for the main boom.

The load measurement is taken with the pressure in the derricking cylin-

9
der. The loads detailed in the Lifting capacity table then lessen with respect
to the weight of both reeved hook blocks and the weight of the heavy
load lattice extension. 4
93
00

Turning a load To turn loads, proceed only in the manner described as follows.

S
51

Keep the acceleration force as low as possible during two-hook

operation.
Bewegen Sie deshalb die Last nur mit geringster Geschwindigkeit!

H As soon as the hoist rope on the main boom is pulled taut, the status dis-
play Actual load will exhibit slight deviations. However, the differences are

H
on the safe side with regard to SLI shutdown.

With two-hook operation, the SLI code for the main boom remains activa-
ted during the entire hoist procedure.
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s
Operating instructions for lattice extension 2 084 770 en 6 - 23
GMK 5100
Heavy load lattice extension
6.6 Turning loads with the heavy load lattice extension

C0985

• Lift the load completely off the ground with the heavy load lattice exten-
sion.

9
• Only now should you attach the load to the hook block of the main
boom as well. 4
93
• Now lift the load with the hook block on the main boom until both slin-
ging points are at the same height.
00
51

C0984

• Slacken the hoist rope on the heavy load lattice extension until the load
is only hanging from the hook block on the main boom.
Turning the load is thus completed.
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6 - 24 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Alphabetical index

H How to use the alphabetical index ➠ GMK 5100 Operating instructions.

To avoid making the index unnecessarily long and unclear, we have not
included every single element from the instrument panel.
These elements, such as rocker switches, warning and indicator lamps as
well as status displays are described and named in detail in the overviews
of chapter 4 and 10 Description of the truck crane.
From there, you will be referred to more detailed descriptions of these ele-
ments.

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Operating instructions for lattice extension 2 084 770 en Alphabetical index - 1

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Alphabetical index - 2 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Index

A Auxiliary single-sheave boom top

installing/removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
possible reeving methods . . . . . . . . . . . . . . . . . . . . . . . 5-3
rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

B Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

organizational measures . . . . . . . . . . . . . . . . . . . . . 1-5 – 1-6
personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . 1-7
proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 – 1-4
safety instructions for truck crane work . . . . . . . . . . . . . 1-8 – 1-9
warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 – 4-25
assembly of boom extensions . . . . . . . . . . . . . . . . . . 4-3 – 4-4

9
CHECKLIST: Installing the 26 m / 34 m boom extension . . . . . . . 4-5
4
CHECKLIST: Removing the 26 m / 34 m boom extension
description of rigging work . . . . . . . . . . . . . . . .
.
.
. . . . . 4-8
4-11 – 4-18
93
driving with a rigged boom extension . . . . . . . . . . . 4-19 – 4-24
folding deflection sheave out/in . . . . . . . . . . . . . . . . . . . 4-15
slinging points on the boom extension . . . . . . . . . . . . . . . . 4-2
00
51

C CHECK LIST:
heavy load lattice extension changing . . . . . . . . . . . . . 6-5, 6-7

E Electrical system
on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 3-55

H Heavy load lattice extension

hoist rope position and remove . . . . . . . . . . . . . . . . . . . 6-14
holding rods folding and unfolding . . . . . . . . . . . . . . . . . 6-12
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
lifting limit switch and anemometer . . . . . . . . . . . . . . . . . 6-16
operation with heavy load lattice extension . . . . . . . . 6-19 – 6-23
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
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rigging work check lists . . . . . . . . . . . . . . . . . . . . . 6-5 – 6-8

SLI-shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Heavy load lattice extension lowering in transport position
heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . 6-13

Operating instructions for lattice extension 2 084 770 en Alphabetical index - 3

GMK 5100
 Heavy load lattice extension lowering in working position
heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . 6-13
Hoist cable
positioning/removing on lattice extension . . . . . . . . . . . . . 3-52
positioning/removing on the boom extension . . . . . . . . . . . 4-16
possible reeving methods on the boom extension . . . . . . . . . 3-54
possible reeving methods on the lattice extension . . . . . . . . . 3-54
Hoist rope
position / remove on the heavy load lattice extension . . . . . . . 6-14
possible reeving methods on the heavy load lattice extension . . 6-15

I Identification
auxiliary single-sheave boom top . . . . . . . . . . . . . . . . 5-1 – 5-2
of the boom extension . . . . . . . . . . . . . . . . . . . . . . 4-1 – 4-2
of the two-stage swing-away lattice extension . . . . . . . . . 3-1 – 3-2
Important information about these operating instructions . . . . . . . . 1-1

L Lattice extension 4 9
93
assembly of lattice extensions . . . . . . . . . . . . . . . . . . . . . 3-3
centre of gravity positions . . . . . . . . . . . . . . . . . . . . . . . 3-4
CHECKLIST: installing two-stage swing-away lattice extension . . . 3-6
00

CHECKLIST: removing two-stage swing-away lattice extension . . . 3-7

CHECKLIST: rigging the 11 m swing-away lattice extension . . . . . 3-9
CHECKLIST: rigging the 18 m swing-away lattice extension . . . . 3-17
51

CHECKLIST: unrigging the 11 m swing-away lattice extension . . 3-13

CHECKLIST: unrigging the 18 m swing-away lattice extension . . 3-21
description of rigging work . . . . . . . . . . . . . . . . . 3-27 – 3-62
driving with rigged lattice extension . . . . . . . . . . . . 3-73 – 3-79
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
folding deflection sheave out/in . . . . . . . . . . . . . . . . . . . 3-51

M Malfunctions
boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

P Possible reeving methods

auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . 5-3
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R Reeving methods
on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Alphabetical index - 4 2 084 770 en Operating instructions for lattice extension

GMK 5100
 Rigging the heavy load lattice extension . . . . . . . . . . . . . 6-9 – 6-18
Run-up rail
folding out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

S SLI
set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
shutdown during work with the boom extension . . . . . . . . . 3-67
shutdown during work with the lattice extension . . . . . . . . . 3-67
shutdown when working with heavy load lattice extension . . . . 6-19

T The units of measurement in US units . . . . . . . . . . . . . . . . . . 1-10

Transport condition
of the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Transport dimensions and weights
in metric units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

9
in US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Turning loads
4
auxiliary single-sheave boom top . . . . . . . . . . . . . . . 5-4 – 5-11
93
with the lattice extension . . . . . . . . . . . . . . . . . . . 3-69 – 3-72
Two-hook operation . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 – 5-11
00
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