Operating Instructions Lattice Extension: 2 084 629 en 2 084 629 en

Operating instructions lattice extension
Vehicle serial number: 2 084 629 en

16.02.2001
Important note
Duplications of any kind and excerpts from

this document are not subject to the alterations
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
alterations service.
© Copyright reserved by Deutsche GROVE GmbH

16.02.2001
The passing on or duplication of this document as well as the use and disclosure of its contents are prohibited
unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration of patent or utility
model are reserved.
2 084 629 en Operating instructions lattice extension GMK 4075

These operating instructions consist of the following chapters:
1 Important information
2 Transport dimensions and weights
3 Two-stage swing-away lattice extension (additional equipment)
4 Boom extension (additional equipment)
5 Auxiliary single-sheave boom top (additional equipment)
6 Index
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Operating instructions lattice extension GMK 4075 2 084 629 en

16.02.2001
2 084 629 en Wartungsanleitung GMK 4075

1
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 Specifications in US units of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10

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Important information
1.1 About these operating instructions
1 Important information
1.1 About these operating instructions
H
All the lattice extensions described in these operating instructions can be
obtained as additional equipment.
Validity of these This operating manual only applies to lattice extensions which were deliv-
operating instruc- ered by Deutsche GROVE GmbH.
tions
In addition, for the operation of the truck crane with a lattice extension de-
scribed in these operating instructions, all details in the included operating
instructions GMK 4075 for which the lattice extension was delivered from the
factory, are applicable.
Prerequisites for The lattice extensions described in these operating instructions may only be
assembly and operated together with a GROVE truck crane GMK 4075 whose serial num-
operation ber is identical with the serial number that is marked on the lattice exten-
sions.
Safety notes For the operation of GMK 4075 with one of the lattice extensions described
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 instructions
of GMK 4075.
Reference to other Cross references to other operating or maintenance instructions are stated
operating instruc- as follows:
tions à Operating instructions GMK 4075, Part 2 Superstructure – Rigging work.
20.02.2001
The number for the chapter on rigging work is found in front on the second
page of the operating instructions indicated.
Operating instructions lattice extension GMK 4075 2 084 629 en 1-1

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 instruc-
tions to highlight particularly important information:
G
This symbol indicates hazards related to the operation described that may
cause personal injury. The type of danger (e.g. danger of fatal injury, per-
sonal injury or risk of crushing) is normally specified in the warning sign.
S
Here dangers which could put objects at risk are pointed out, e.g. damage
to the truck crane, the load or the environment.
B
This symbol alerts you to situations where there is a danger of receiving an
electric shock.
O
This symbol reminds you that you are working with substances which pose
a risk to the environment. Take particular care. Further information on han-
dling substances that pose a risk to the environment; à
Maintenance
manual, Chapter Safety and environmental protection.
The vertical line to the left of the warning text indicates: this text, regardless
of its length, relates to the warning symbol.
H
The hand with the pointing finger indicates passages that contain additional
instructions and tips with regard to truck crane operation.
s This symbol indicates that the topic is continued on the next page. Turn to
the next page.
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1-2 2 084 629 en Operating instructions lattice extension GMK 4075

1.3 Proper use
1.3 Proper use

The truck crane GMK 4075 is constructed in accordance with the state of the
art and the recognized safety regulations. Nevertheless, personal injury to
the operator or a third party as well as damage to the crane and other prop-
erty may occur during use.
The truck crane may only be modified with the consent of the manufacturer.
The truck crane GMK 4075 must only be used in proper working condition
and for its intended purpose, while taking into account safe operation and
any possible hazards.
Malfunctions that may affect the safe operation of the unit are to be cor-
rected immediately.
The GMK 4075 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.
The GMK 4075 truck crane is intended solely for vertically lifting loads
whose weight and centre of distribution are known, with a hook block
reeved on the hoist rope and only in the permitted rigging modes. Any other
use of the crane is not considered to represent proper usage.
The manufacturer is not liable for damage resulting from the improper or
unauthorized use of the truck crane GMK 4075. The user shall take on full
responsibility for any such use.
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.
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s
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, increasing the radius by pulling the raised load at
an angle (e.g. with a chain hoist)
– misuse of the outrigger pressure display as a safety function to prevent
overturning after an SLI shutdown (outrigger pressure greater than 0 t)
– road driving in an unauthorized driving mode (axle load, dimension)
– moving the rigged crane in an unauthorized driving mode
– the transportation of raised loads by moving the truck crane
– use of equipment that is not authorized for use with the crane
– transporting passengers on unauthorized parts of the vehicle
– 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 suffi-
ciently long break
– usage for any kind of sport or recreation event, especially for bungee
jumping.
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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 removed
from the truck crane. You must have read and understood the operation and
safety instructions in these operating instructions, and comply with them
when working.
In addition to the operating instructions and the lifting capacitytable, ob-
serve all general, statutory and otherwise applicable regulations concerning
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.
Ensure that those appointed to work on the truck crane are given the infor-
mation required to carry out the work before starting operations. Give your
employees (e.g. banksmen, slingers, rigging personnel) appropriate in-
structions.
Ensure that the maintenance personnel possess the necessary know-how to
safely operate the crane. Ensure that the maintenance personnel have ac-
cess to the operating instructions.
Only properly trained or instructed personnel may carry out work on the
truck crane.
Responsibilities related to crane operation, rigging, maintenance and repair
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 sfety and warning signs on the truck crane remain legible.
s
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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 extinguishers
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 manner
that the safety conditions are affected, e.g. if you doubt the truck crane´s op-
erating safety, stop the machine immediately and inform the appropriate re-
sponsible persons.
Do not make any changes to the programmable controlsystems (e.g. the

SLI).
Do not modify or mount attachments to the truck crane without the consent
of the manufacturer, if such changes could affect the safety of the unit. This
also applies to
– the installation of safety devices,

– the adjustment of safety devices and valves.
Welding work on load-bearing parts may only be carried out by properly
qualified personnel with the manufacturer's permission. To avoid any
damage, especially to electronic parts, there are certain steps you must take
before doing any welding work. You should thus always consult GROVE
Customer Support before doing any welding work.
Ensure that both the prescribed periods and the periods specified in the op-
erating and maintenance instructions for regular testing, inspection and
maintenance work are maintained.
Replace the hydraulic hose lines, or have them replaced, at the prescribed
intervals, 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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1.5 Personnel qualifications
1.5 Personnel qualifications

These operating instructions are not a training manual for prospective crane
operators.
All descriptions are written explicitly for crane operators who have been
trained to operate truck cranes.
Employees in training may only operate the truck crane under strict super-
vision.
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.
– You must be familiar with and have understood the operating instruc-
tions.
– You must be familiar with and have understood the accident prevention
regulations.
– You must fulfil all physical and mental requirements for truck crane oper-
ation, e.g. perfect sight and hearing and the ability to react quickly.
Please refer to the section in the Safety manual titled You as crane driver and
operator.
Only experienced personnel familiar with the applicable accident preven-

tion regulations are authorized to sling loads and train crane operators.
Your responsibilities as a crane operator (including those concerning traffic

regulations) must be clearly defined. You must be in a position to refuse 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 mainte-
nance work on the truck crane.
Deutsche GROVE GmbH gives general and type-related crane operator and
technical courses.
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1.6 Safety instructions for truck crane work

Carefully select a safe site for the truck crane to stand from where you can
work safely.
Check over the truck crane before beginning crane work. Check the condi-
tion of the truck crane carefully using the check lists in the operating instruc-
tions. Do not assume that everything is in working order simply because it
was in working order when work was last completed.
Check daily before starting to work with the crane that all guards and safety
devices are correctly fitted and that they are all in a proper 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.
Walk only on those machine parts which are equipped with appropriate
steps and railings and therefore guarantee safety. During rigging and main-
tenance work on machine sections above body height which have no appa-
ratus for accessing, always use the extension ladder supplied (e.g. when
reeving the hoist rope on the boom head).
Keep all handles, steps, step treads and ladders free of dirt, snow and ice.
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 instruments
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 us-
ing 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 vertical
position and does not drag, injure helpers or fall into the hoist rope diago-
nally (e.g. from a vehicle or scaffolding) Inform banksmen and helpers
about this as well.
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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 unauthorized use.
Crane work carried out in the vicinity of supply lines such as oil, gas or other
supply lines is dangerous and requires that special precautionary measures
be taken. Please refer to the section titled Crane operation under special operat-
ing conditions in the Safety manual, and observe the relevant national regula-
tions.
20.02.2001

1.7 Specifications in US units of measurement
1.7 Specifications in US units of measurement

These operating instructions use mainly metric units of measurement.
Should you be working in a country that uses US units of measurement, re-
fer to the following table for a comparison of the units.
– The first column shows the metric units of measurement.

– 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 leg-
ibility if both units of measurement are stated (in Chapter 2, Transport di-
mensions and weights and in the diagrams showing the composition of the
individual lattice extensions).
Prescribed length in Corresponding length in Rounded length in

metric measuring units US measuring units US measuring units
According to the lifting in these operating
capacity table instructions
10 m 32.8 ft 33 ft
Swing-away lattice extension
17 m 55.8 ft 56 ft
Two-stage swing-away lattice
extension
22 m 72.2 ft 72 ft
Boom extension
27 m 88.6 ft 89 ft
Boom extension
7 m section 23.0 ft 23 ft
5 m section 16.4 ft 16 ft
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1 - 10 2 084 629 en Operating instructions lattice extension GMK 4075

2
2 Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1
2.1 In metric units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

2.1.1 Two-stage swing-away lattice extension and boom extension . . . . . . . . . . . . . 2 - 1
2.1.2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
2.2 In US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
2.2.1 Two-stage swing-away lattice extension and boom extension . . . . . . . . . . . . . 2 - 3
2.2.2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
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16.02.2001

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 ex-
tensions in metric units.
2.1.1 Two-stage swing-away lattice extension and boom extension
Description Length x width x Weight (kg)

height (m)
Two-stage swing-away lattice 10.50 x 0.90 x 1.20 1350
extension (complete, folded
together)
10 m section 10.50 x 0.90 x 1.20 1 060
7 m section 7.00 x 0.50 x 0.60 300
5 m section with deflection 5.20 x 0.90 x 1.20 460
sheave
5 m section without deflec- 5.20 x 0.90 x 1.20 350
tion 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 complete with pins
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2.1 In metric units
Blank page
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2.2 In US units
2.2 In US units
This section contains the transport dimensions and weights of the lattice ex-
tensions 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 35.0 x 3.0 x 4.0 2980
extension (complete, folded
together)
10 m section 35.0 x 3.0 x 4.0 2340
7 m section 23.0 x 1.7 x 2.0 670
5 m section with deflection 17.2 x 3.0 x 4.0 1020
sheave
5 m section without deflection 17.2 x 3.0 x 4.0 780
sheave
2.2.2 Auxiliary single-sheave boom top
Description Length x Width x Weight (lbs)

Height (ft)
Auxiliary single-sheave boom 3.3 x 1.4 x 3.3 140
top complete with pins
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2.2 In US units
Blank page
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3
3 Two-stage swing-away lattice extension
(additional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1
3.1 Additional operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1

3.1.1 In the crane cabin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
3.1.2 Operating and display instruments on the lattice extension . . . . . . . . . . . . . . . 3 - 4
3.2 Identification of the two-stage swing-away lattice extension . . . . . . . . . . . . . . . 3 - 5
3.3 Assembly of the lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
3.4 Centres of gravity for slinging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
3.5 Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9

3.5.1 Overview of the required rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 9
3.5.2 CHECK LIST: Installing the (two-stage) swing-away lattice extension . . . . . . . 3- 10
3.5.3 CHECK LIST: Uninstalling (two-stage) swing-away lattice extension . . . . . . . . 3- 12
3.5.4 CHECK LIST: Rigging the 10 m swing-away lattice extension . . . . . . . . . . . . . . 3- 14
3.5.5 CHECK LIST: Unrigging the 10 m swing-away lattice extension . . . . . . . . . . . . 3- 18
3.5.6 CHECK LIST: Rigging the 17 m two-stage swing-away lattice extension . . . . . 3- 23
3.5.7 CHECK LIST: Unrigging the 17 m two-stage swing-away lattice extension . . . 3- 27
3.6 Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33
3.6.1 Preparing the truck crane for rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 33
3.6.2 Checking the transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 35
3.6.3 Hose drum for hydraulic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 38
3.6.4 Folding the run-up rail out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 41
3.6.5 Connections with folded lattice extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 42
3.6.6 Pin connections on the main boom head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 49
3.6.7 Pin connections on the latticeextension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 53
3.6.8 Swinging the lattice extension onto the main boom head . . . . . . . . . . . . . . . 3- 55
3.6.9 Swivelling the lattice extension when rigging . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 56
3.6.10 Electrical connections on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . 3- 58
3.6.11 Establishing/disconnecting the hydraulic connection . . . . . . . . . . . . . . . . . . . . 3- 60
3.6.12 Folding out / in the deflection sheaves on the 10 m section . . . . . . . . . . . . . . . 3- 61
3.6.13 Positioning/removing the hoist cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 64
3.6.14 Lifting limit switch on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 66
3.6.15 Anemometer on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 68
3.6.16 Derricking the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 69
3.6.17 Transportation on a separate vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 70
3.7 Raising and setting down the main boom with rigged lattice extension . . . . . . 3 - 71
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3.8 Telescoping with rigged lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 73

3.9 Operation with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 75
3.9.1 SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 75
3.9.2 Procedure if the permissible wind speed is exceeded . . . . . . . . . . . . . . . . . . . . 3 - 76
3.10 Turning loads with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77
3.10.1 Prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77
3.10.2 Setting SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 78
3.11 Driving with rigged crane and installed lattice extension. . . . . . . . . . . . . . . . . . . 3 - 83
3.11.1 Driving route. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 83
3.11.2 Boom positions and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 84
3.11.3 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 86
3.12 Malfunction when working with lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 3 - 91
3.13 Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 93

3.13.1 Modules in need of protection during cleaning work. . . . . . . . . . . . . . . . . . . . . 3 - 93
3.13.2 Maintenance work M1, monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 94
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Two-stage swing-away lattice extension (additional equipment)
3.1 Additional operating and display elements
3 Two-stage swing-away lattice extension

(additional equipment)

When the GMK 4075 is equipped with lattice extension, certain operating
and display elements in the crane cab also apply to the operation of the lat-
tice extension. The following sections describe:
– all operating and display elements in the crane cabine required for the op-
eration of the lattice extension.
– the operating elements located directly on the lattice extension.
20.02.2001

3.1.1 In the crane cabin
In the crane cabin there are additional operating and display elements on
the right control console on the display crane control and on the plug-in mod-
ule of the safe load indicator.
At the control At the right control console there is an additional rocker switch and the right
console right control lever has an additional function.
The rocker switch lower lattice extension on / off (1) is used for switching on and
off the derricking gear at the lattice extension.
There is an indicator lamp in the rocker switch. The indicator lamp shows,
whether the derricking gear is switched on or off.
Indicator lamp is dimly illumi- Derricking gear is switched off
nated:
Indicator lamp is brightly illumi- Derricking gear is switched on
nated:
After switching on the ignition that condition is reproduced, which was

saved after the last switch-off.
Switching on the derricking gear: Indicator lamp is slightly illuminated.

Press rocker switch upwards once; the
indicator lamp will then be brightly illu-
minated.
If the control lever is assigned more than one function, all other driving
gears which are assigned the same movement of the control lever are
switched off. Indicator lamps in the corresponding rocker switches are
dimly illuminated.
Switching off the derricking gear: Indicator lamp is brightly illuminated

Press rocker switch upwards once; the
indicator lamp will then be dimly illu-
minated.
If the control lever is assigned more than one function, the derricking gear
can also be switched off by switching on a driving gear which is assigned
the same movement of the control lever.
If the derricking gear of the lattice boom is switched on, the lattice boom is
lowered with the right control lever.
7
Raise the lattice extension M ove the control lever to the left
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Lower the lattice extension Control lever to the right, control lever to
the left

On the crane In case of an electrically connected lattice extension there are various dis-
control display play and setting possibilities on the crane control display. For calling up
menus and for setting àGMK 4075 Operating instructions, Part 2 Superstruc-
ture.
Indicator lamp lower lattice extension on / off (1) is displayed in the main
menu. The indicator lamp shows, whether the derricking gear of the lattice
extension is switched on or off.
Glows green: Derricking gear of the lattice extension is switched on
Glows red: Derricking gear of the lattice extension is switched off
In the sub-menu driving gear speed, the symbol (1) for the lattice extension
operation is shown in yellow and additionally the maximum speed for low-
ering the lattice extension can be entered for other driving gears.
In the sub-menu operating hours counter, the value in the display under the
symbol for the lattice extension (1) increases to the extent of time, in which
the lattice extension is derricked.
At the safe load The following displays and membrane switches are active on the safe load
indicator indicator with electrically connected lattice extension.
Status display for length of lattice extension with a membrane switch

1/0 Displays the length of the lattice extension in metres. The status display is
activated when an SLI code for working with the lattice extension is entered
in the rigging mode status display. The displayed length is obtained from
the entered SLI code. If the entry mode is activated in the rigging mode dis-
play, pressing the membrane button repeatedly displays other values which
are permitted according to the lifting capacity table in ascending order.
When the greatest length is reached and the membrane button is pressed
again, the display starts again at the beginning with the lowest value.
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Status display for angle of lattice extension with membrane switch

1%0 Displays the current measured angle of lattice extension to the main boom
in degrees. The status display is activated when an SLI code for working
with the lattice extension is entered in the rigging mode status display. No
values can be selected on the display.
K Membrane button with indicator lamp for angle of lattice extension

After pressing the switch, the green indicator lamp in the button lights up
and the current angle of the lattice extension, in relation to the horizontal is
shown in the information status display.
3.1.2 Operating and display instruments on the lattice extension
Switch units There are two switch units each with two push buttons on the lattice exten-
sion.
The push buttons (1) and (2) have the same

function on both the switch units.
1 Raise lattice extension push-button

2 Lower lattice extension push-button
The lattice extension is lowered or raised as

long as the push-button is pressed or until the
end position or a switch-off point is reached.
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3.2 Identification of the two-stage swing-away lattice extension
3.2 Identification of the two-stage swing-away lattice

extension
The two-stage swing-away lattice extension is designed for the truck crane
with which it was delivered. 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 10 m section on the fixed section,
– the 10 m section on the inclinable section,
– the 7 m section.
S
Only operate the truck crane with sections of the two-stage swing-away
lattice extension that have the same serial number as the crane.
The SLI is set only for this two-stage swing-away lattice extension.
This prevents malfunctions and damage.
H
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 truckcranes, 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
local GROVE Customer Support.
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3.2 Identification of the two-stage swing-away lattice extension
Serial numbers on The 10 m section consists of a fixed section and an inclinable section.
10 m section
On the inclinable section the serial number (1)

is at the front on a sheet to the right of the de-
flection sheave.
On the fixed section the serial number (2) is at

the rear on a sheet in the upper boom.
Serial number on
7 m section
On the 7 m section the serial number (1) is at

the rear on a sheet in the upper boom.
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3.3 Assembly of the lattice extensions
3.3 Assembly of the lattice extensions
10 m swing-away lattice extension

(33 ft swing-away lattice extension)
10 m section
(33 ft section)

10 m section 7 m section
(33 ft section) (23 ft section)
H
The lengths of 10 m and 17 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 10 m section and 7 m section have been adapted to these
lengths. The total length of the individual sections is greater or smaller;
à Transport dimensions and weights, p. 2 - 1.
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3.4 Centres of gravity for slinging
3.4 Centres of gravity 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 load bear-
ing capacity; àTransport dimensions and weights, p. 2 - 1.
In this way you prevent the lattice extension from slipping out, falling and
causing injury during installation or removal.
The distances are always measured from the centre of the fork elements.
For the 17 m two-stage swing-away lattice extension, swung out, the dis-
tance for the centre of gravity is (1) = 5900 mm.
For the 17 m two-stage swing-away lattice extension, folded, the distance

for the centre of gravity is (2) = 4600 mm.
For the 10 m two-stage swing-away lattice extension on its own, the dis-
tance for the centre of gravity is (3) = 3920 mm.
For the 7 m two-stage swing-away lattice extension on its own, the distance
for the centre of gravity is (4) = 3060 mm.
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3.5 Checklists for rigging work
3.5.1 Overview of the required rigging work
There are different initial states for rigging the lattice extension, depending
on whether
– the lattice extension is folded at the side of the main boom or

– The lattice extension has been dismantled for on-road driving, Driving
mode tables à Operating Instructions GMK 4075, Part 1 Carrier – Driving the
truck crane.
The following table shows you which check list describes the required
rigging work for your initial state.
Initial state Corresponding rigging work

CHECK LISTS:
The lattice extension is Rigging the 10 m swing-away
located at a side on lattice extension; à p. 3 - 10.
the main boom Unrigging the 17 m two-stage
before the swing-away-lattice extension;
crane
operation
à p. 3 - 23.
CHECK LIST:
The lattice extension was Installing two-stage swing-
removed completely
away lattice extension;
à p. 3 - 10.
CHECK LISTS:
Unrigging the 10 m swing-
The lattice extension must away lattice extension;
be folded to the side of the à p. 3 - 18.
main boom Unrigging the 17 m two-stage
after the
crane swing-away lattice extension;
operation à p. 3 - 27.
CHECK LIST:
The lattice extension is to be Removing the two-stage swing-
removed for on-road driving away lattice extension;
à p. 3 - 12.
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3.5.2 CHECK LIST: Installing the (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.
Prerequisites:
– The truck crane is on outriggers or the main boom is placed on the boom
support.
– An auxiliary crane is available.
1. If necessary, connect the hose drum for hydraulic supply;

à Hose drum for hydraulic supply, p. 3 - 38.
2. Check the transport condition of the (two-stage) swing-away lattice ex-

tension; à Transport condition with removed lattice extension, p. 3 - 37.
3. Sling (two-stage) swing-away lattice extension on auxiliary crane;

à Centres of gravity for slinging, p. 3 - 8.
4. Lift (two-stage) swing-away lattice extension in front of the main boom

with the auxiliary crane and lock the 10 m section to the right of the
main boom head; àPin connections on the main boom head, p. 3 - 49.
5. Establish hydraulic connection between the lattice extension and the

main boom; àEstablishing/disconnecting the hydraulic connection,
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p. 3 - 60.

6. Establish electrical connection between the lattice extension and the

main boom; à Electrical connections on the lattice extension, p. 3 - 58.
7. Attach the guide rope to the head of the 10 m section.
H
If the lattice extension needs to be rigged in front of the main boom,
proceed as from point 10.
8. If the lattice extension is to be folded up at the side of the main boom,

fold out run-up rail; à Folding the run-up rail out/in, p. 3 - 41.
9. The other types of rigging work for folding up the lattice extension at
the side are described in the CHECK LIST: Unrigging the 10 m swing-away
lattice extension from the point onwards 12. à
p. 3 - 19.
10. If the lattice extension needs to be rigged in front of the main boom,
attach guide ropes to the head of the 10 m section.
The other types of rigging work for the 10 m swing-away lattice exten-
sion are described in the CHECK LIST: Rigging the 10 m swing-away lattice
extension from the point onwards 14. à
p. 3 - 16.
The other types of rigging work for the 17 m two-stage swing-away lat-
tice extension are described in the CHECK LIST: Rigging the 17 m swing-
away lattice extension from the point onwards 13. à
p. 3 - 25.
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Operating instructions lattice extension GMK 4075 2 084 629 en 3 - 11

3.5.3 CHECK LIST: Uninstalling (two-stage) swing-away lattice

extension
H
Prerequisites:
support.
1. Carry out all of the rigging work for a rigged 10 m swing-away lattice
extension listed in the CHECK LIST: Unrigging 10 m swing-away lattice ex-
tension up to and including point 9.; àp. 3 - 19.
2. Carry out all of the rigging work for a rigged 17 m two-stage swing-
away lattice extension listed in the CHECKLIST: Unrigging 17 m swing-
away lattice extension up to and including point 15. are listed;
à p. 3 - 29.
3. Disconnect hydraulic connection between the lattice extension and the

main boom; à
Establishing/disconnecting the hydraulic connection,
p. 3 - 60.
4. Disconnect electrical connection between the lattice extension and the

main boom; àElectrical connections on the lattice extension, p. 3 - 58.
5. Slinging (two-stage) swing-away lattice extension on auxiliary crane;

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6. Remove locking pins on both sides between 10 m section and main

boom head and place (two-stage) swing-away lattice extension onto
separate vehicle using auxiliary crane; à
Pin connections on the main
boom head, p. 3 - 49, à
Transportation on a separate vehicle, p. 3 - 70.
7. Check the transport condition of the (two-stage) swing-away lattice ex-

tension; àTransport condition with removed lattice extension, p. 3 - 37.
8. If necessary, remove hose drum connection for hydraulic supply;

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3.5.4 CHECK LIST: Rigging the 10 m swing-away lattice extension
H
1. Prepare the truck crane for rigging the swing-away lattice extension;
à Preparing the truck crane for rigging, p. 3 - 33.
2. If necessary, connect the hose drum for hydraulic supply; à Hose drum
for hydraulic supply, p. 3 - 38.
3. Check if the lattice extension was unrigged properly and is in transport

condition; à Transport condition with lattice extension folded at the side,
p. 3 - 37.
4. Folding out the run-up rail; à Folding the run-up rail out/in, p. 3 - 41.
H
If only the 10 m section is folded at the side of the main boom – proceed as
from point 7.
5. Move the connection in the middle area on 10m section;

à Joint at the 10 m section, p. 3 - 46.
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6. Release connection at the pivot point between 10 m section and 7 m

section; àPin connections on the latticeextension, p. 3 - 53.
7. If only the 10 m section is folded at the side of the main boom, remove
connection between 10 m section and main boom (rear); à
Connection
between 10 m section and main boom, p. 3 - 48.

main boom; à 10 m swing-away lattice extension, p. 3 - 58.

p. 3 - 60.
10. Swing 10 m section onto the main boom head; à Swinging the lattice
extension onto the main boom head, p. 3 - 55.
11. Fasten 10 m section onto the main boom head with pins on right-hand
side; à Pin connections on the main boom head, p. 3 - 49.
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12. Secure the lattice extension on the main boom with guide rope;
à Securing lattice extension with cord, p. 3 - 34.
13. Release the connection in the front area, for this, if necessary, press
down the slewing axle mechanically; à
Removing the connection,
p. 3 - 44.
14. Swing the 10 m section in front of the main boom head; à Swivelling
the lattice extension when rigging, p. 3 - 56.
15. Pin the 10 m section onto the main boom head, on left-hand side;
à Pin connections on the main boom head, p. 3 - 49.
16. Fold out both deflection sheaves on the 10 m section; à Folding out /
in the deflection sheaves on the 10 m section, p. 3 - 61.
17. Place the hoist cable over both deflection sheaves and head sheave of
the 10 m section; àPositioning/removing the hoist cable, p. 3 - 64.
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18. Move the anemometer from the head of the main boom to the head of
the 10 m section; à
Anemometer on the lattice extension, p. 3 - 68.
19. Move the lifting limit switch from the head of the main boom to the
head of the 11 m section; à
Lifting limit switch on the lattice extension,
p. 3 - 66.
20. Reeve the hoist cable on the hook block; à Possible reeving methods on
the lattice extension, p. 3 - 65.
21. Attach the lifting limit switch weight and guide hoist rope through the
weight; à Operating instructions GMK 4075, Part 2 Superstructure – Rig-
ging work.
22. SLI code according to the Enter the lifting capacity table for the actual rig-
00== ging mode of the truck crane with the 10 m swing-away lattice exten-
sion, setting the rigging mode à
Operating instructions GMK 4075, Part 2
Superstructure – Crane operation.
Further working steps for raising the boom; à p. 3 - 71.

Telescoping with the rigged lattice extension; à p. 3 - 73.
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3.5.5 CHECK LIST: Unrigging the 10 m swing-away lattice extension
H
1. Prepare the truck crane for unrigging; à Preparing the truck crane for rig-
ging, p. 3 - 33.
2. Retract the main boom completely and lower it into the horizontal
position.
3. Enter SLI code according to lifting capacity table for the actual rigging
00== mode of the truck crane with the 10 m swing-away lattice extension,
setting the rigging mode à Operating instructions GMK 4075, Part 2 Super-
structure – Crane operation.
4. Remove the lifting limit switch weight and move lifting limit switch
from the head of the 10 m section to the head of the main boom;
à Lifting limit switch on the lattice extension, p. 3 - 66.
5. Unreeve the hoist cable from the hook block and remove it from the lat-
tice extension; àPossible reeving methods on the lattice extension,
p. 3 - 65.
6. Remove anemometer; à Anemometer on the lattice extension, p. 3 - 68.

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7. Fold in both deflection sheaves on the 10 m section; à Folding out / in

the deflection sheaves on the 10 m section, p. 3 - 61.
8. Reel hoist cable up to the main boom head.
10. Remove left-hand locking pin between the 10 m section and the main
boom head; à
Pin connections on the main boom head, p. 3 - 49.
11. Raise the main boom completely; à Derricking the lattice extension,
p. 3 - 69.
12. Swing the 10 m section onto the main boom; à Swivelling the lattice ex-
tension when rigging, p. 3 - 56.
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13. Lower the lattice extension so that it is positioned on the run-up rail.
14. Establish the connection in the front area; à Establishing a connection,

p. 3 - 45.
15. Remove right hand locking pin between the 10 m section and the main
boom head; à
16. Swing the 10 m section on the run-up rail onto the main boom;
à Swivelling the lattice extension when rigging, p. 3 - 56.
17. Secure the connection in the front area; à Securing the connection,
p. 3 - 43.
H
If the 7 m section is not attached to the main boom – proceed as from
Point 20.
18. Move the connection in the middle area 7 m section / 10 m section;

à 7 m section / 10 m section joint, p. 3 - 45.
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19. Establish the connection at the pivot point between 10 m section and
7 m section; àPin connections on the latticeextension, p. 3 - 53.
H
If the 7 m section is attached to the main boom – proceed as from point 21.
20. Establish the connection between 10 m section and the main boom in
the rear area; àConnection between 10 m section and main boom, p. 3 - 48.
21. Remove electrical connection between the lattice extension and the
main boom; à
10 m swing-away lattice extension, p. 3 - 58.
main boom; à
p. 3 - 60.
23. Check whether the lattice extension is in transport condition;

à Checking the transport condition, p. 3 - 35.
24. Folding in the run-up rail; à Folding the run-up rail out/in, p. 3 - 41.
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3.5.6 CHECK LIST: Rigging the 17 m two-stage swing-away lattice

extension
H
1. Prepare the truck crane for rigging the swing-away lattice extension;
à Preparing the truck crane for rigging, p. 3 - 33.
3. Check if the lattice extension was unrigged properly and is in transport

condition; à Transport condition with lattice extension folded at the side,
p. 3 - 37.
4. Folding out the run-up rail; à Folding the run-up rail out/in, p. 3 - 41.

6. Remove the connection between 7 m section and the main boom in the
rear area; à
Connections in the rear area, p. 3 - 47.
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main boom; à 10 m swing-away lattice extension, p. 3 - 58.

p. 3 - 60.
9. Swinging the lattice extension onto the main boom head; à Swinging
the lattice extension onto the main boom head, p. 3 - 55.
10. Fasten 10 m section onto the main boom head with pins on right-hand
side; à Pin connections on the main boom head, p. 3 - 49.
11. Secure the lattice extension on the main boom with guide rope;
à Securing lattice extension with cord, p. 3 - 34.
12. Remove the connection in the front area, for that, if necessary, press
down the slewing axle mechanically; à
Removing the connection,
p. 3 - 44.
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13. Swing the lattice extension in front of the main boom head;
14. Pin the 10 m section onto the main boom head, on left-hand side;
16. Move the connection in the middle area on 10 m section;

à Joint at the 10 m section, p. 3 - 46.
17. Swinging the 7 m section in front of the 10 m section;

à Swing the 7 m section in front of the 10 m section, p. 3 - 57.
18. Fasten the 7 m section on left-hand side in front of 10 m section with a

pin; à Pin connections on the latticeextension, p. 3 - 53.
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19. Establish electrical connection between the 10 m and 7 m sections;

à 17 m two-stage swing-away lattice extension, p. 3 - 59.
20. Fold out both deflection sheaves on the 10 m section; à Folding out /
in the deflection sheaves on the 10 m section, p. 3 - 61.
21. Place the hoist cable over both deflection sheaves and head sheave of
the 7 m section; àPositioning/removing the hoist cable, p. 3 - 64.
p. 3 - 66.
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weight; à Operating instructions GMK 4075, Part 2 Superstructure – Rig-
ging work.
26. SLI code according to the enter the lifting capacity table for the actual rig-
00== ging mode of the truck crane with the 17 m swing-away lattice exten-
sion, setting the rigging mode à
Operating instructions GMK 4075, Part 2
Superstructure – Crane operation.
H
Further working steps for raising the boom; à p. 3 - 71.
Telescoping with the rigged lattice extension; à p. 3 - 73.
3.5.7 CHECK LIST: Unrigging the 17 m two-stage swing-away lattice

extension
H
ging, p. 3 - 33.
2. Retract the main boom completely and lower it into the horizontal po-
sition.
3. Enter SLI code according to lifting capacity table for the actual rigging
00== mode of the truck crane with the 17 m swing-away lattice extension, set-
ting the rigging mode à Operating instructions GMK 4075, Part 2 Super-
structure – Crane operation.
à
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Lifting limit switch on the lattice extension, p. 3 - 66.
s
p. 3 - 65.
7. Remove hoist rope from the head sheave on the 7 m section and guide
it to the ground on the lefthadn side of the lattice extension.
H
If the 7 m section needs to be removed and only the 10 m section at the side
of the main boom needs to be folded, proceed as from point 12.
9. Remove the locking pins on the left-hand side between 7 m section and
10 m section; à
Pin connections on the latticeextension, p. 3 - 53.
10. Swinging the 7 m section in front of the 10 m section; à Swing the 7 m

section in front of the 10 m section, p. 3 - 57.
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12. If the 7 m section needs to be removed, attach 7 m section on auxiliary

crane, remove all locking pins between the 7 m section and the 10 m
section and place 7 m section on a separate vehicle.
13. Fold in both deflection sheaves on the 10 m section; à Folding out / in

the deflection sheaves on the 10 m section, p. 3 - 61.
16. Remove left-hand locking pin between the 10 m section and the main
boom head; à
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p. 3 - 69.
18. Swinging the lattice extension onto the main boom; à Swivelling the
lattice extension when rigging, p. 3 - 56.
19. Lower the lattice extension so that it is positioned on the run-up rail.
20. Establish the connection in the front area; à Establishing a connection,

p. 3 - 45.
21. Remove right hand locking pin between the 10 m section and the main
boom head; à
Pin connections on the main boom head, p. 3 - 49. 20.02.2001

22. Swing the lattice extension on the run-up rail onto the main boom;
23. Secure the connection in the front area; à Securing the connection,
p. 3 - 43.
H
If the 7 m section has been removed, proceed from point 25.
24. If the 7 m section has been removed, establish a connection between

the 10 m and the main boom; à
Connection between 10 m section and
main boom, p. 3 - 48.
25. Remove electrical connection between the lattice extension and the
main boom; à
10 m swing-away lattice extension, p. 3 - 58.
main boom; à
p. 3 - 60.
27. Check whether the lattice extension is in transport condition;

à Checking the transport condition, p. 3 - 35.
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28. Folding in the run-up rail; à Folding the run-up rail out/in, p. 3 - 41.
29. If necessary, remove hose drum connection for hydraulic supply ;

20.02.2001

3.6 Description of rigging work
3.6.1 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 the following prerequisites are met, lowering into the horizontal position
with lattice extension/boom extension and a slewing range of 360° is per-
mitted and is monitored by the SLI; àRaising and setting down the main boom
with rigged lattice extension, p. 3 - 71.
Requirements for Before you rig a lattice extension or the boom extension, the following re-
rigging quirements must be met:
– The swing-away lattice extension is mounted on the side of the main

boom and is in transport condition.
– 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 by the outrigger span required acc. to the
lifting capacity table for the planned operation with the lattice extension and
is aligned horizontally.
– The main boom is completely retracted and has been lowered into hori-
zontal position.
– The telescoping cylinder is locked in telescopic section IV and is retracted
as far as possible just before the start of rigging so that all telescoping
parts are fully retracted.
– If the truck crane is equipped with two hoists with additional equipment,
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 horizontal
unrigging position, the following requirements must be met:
– No other load is raised apart from the hook block.

– 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 outrigger span prescribed for oper-
ation with the rigged lattice extension according to the lifting capacity table.
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– The main boom is fully retracted (0/0/0/0).

– The telescoping cylinder is locked in telescopic section IV and is retracted
as far as possible just before the start of rigging so that all telescoping
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 of
extension with its own accord when you remove the last connection that held the lattice ex-
cord tension at the side of the main boom.
You must therefore secure the lattice exension 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 be-
fore 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 persons
in the slewing range.
Secure the lattice extension as follows:
• Attach a cord (2) at the front of the lattice ex-

tension.
• Guide the cord underneath the lattice exten-
sion, 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 to the carrier). Leave enough play in the cord that
it is tight only when you swing the lattice extension towards the main boom
head later on.
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3.6.2 Checking the transport condition
For transportation you must establish certain connections between both

parts of the lattice extension. The connections which need to be established
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 de-
scribed 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 main
boom or the individual components of the lattice extension hitting each
other and becoming damaged.
You must check transport condition:

– After unrigging the lattice extension, before you drive the truck crane with
the lattice extension folded at the side or work with the main boom.
– Before installation and before rigging the lattice extension.
The corresponding checklists require that the lattice extension is in trans-
port condition.
The following paragraphs and the diagram show the necessary connections
for the transport condition with the lattice extension folded at the side and
removed.
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s
20.02.2001

Transport condi- The transport condition with the lattice extension folded at the side is cre-
tion with lattice ated when all of the following connections are established.
extension folded
• Check the connections and establish them if necessary.
at the side
If 7 m section and 10 m section are folded at the side:
– The 10 m section is locked at the slewing axle (1) in front on the main
boom and the slewing axle is secured with a retaining pin (2);
à Establishing a connection, p. 3 - 45,
à Securing the connection, p. 3 - 43.
– The pins (4) are inserted on the pivot point between the 7 m section and
Connection on the pivot point, p. 3 - 54.
– The connection (7) in the middle area is in the position 7 m section /
10 m section; à
7 m section / 10 m section joint, p. 3 - 45.
– The connection (5) between 7 m section and main boom in the rear area
is established ; à
Connection between 7 m section and main boom, p. 3 - 47.
If the 10 m section only is folded at the side:
– The 10 m section is locked at the slewing axle (1) in front on the main
boom and the slewing axle is secured with a retaining pin (2);
à Establishing a connection, p. 3 - 45,
à Securing the connection, p. 3 - 43.
– The connection between the 10 m section and the main boom in the rear
area is established (6); à
Connection between 10 m section and main boom,
p. 3 - 48.
If the 7 m section only is folded at the side:
– The connection in the middle area is in the position 7 m section / main
boom (3); à7 m section / main boom joint, p. 3 - 46.
– The connection between 7 m section and the main boom in the rear area
is established; à
Connection between 7 m section and main boom, p. 3 - 47.
Transport condi- The transport condition for the removed lattice extension is established
tion with removed when all of the following connections have been made.
lattice extension
• Check the connections and establish them if necessary.
– The connections on the pivot point between the 7 m section and the
10 m section have been established (4); à
Connection on the pivot point,
p. 3 - 54.
– The connection in the middle area is in the position 7 m section / 10 m
section (7); à
7 m section / 10 m section joint, p. 3 - 45.
20.02.2001

3.6.3 Hose drum for hydraulic supply
The hydraulic supply for the lattice extension is provided through a hose
drum on the left-hand side of the main boom.
If the main boom is used for longer periods of time, the hose drum's
hydraulic connections should be brought into the Main boom operation
position.
This prevents unnecessary reeling and unreeling of the hose.
The following rigging processes are described in this section:

– Locking device for transportation; à Locking device for transportation,
p. 3 - 38.
– Hydraulic connection, Working with the lattice extension position and main
boom operation position; à
Hydraulic connection, p. 3 - 39.
Locking device for The hose drum is equipped with an anti-twist device. The anti-twist device
transportation prevents the hose drum twisting unchecked against the holder when releas-
ing the strain relief because of initial tension.
G
Risk of accidents from uncontrolled turning of hose drum.
You may release the anti-twist device only when you have attached the
strain relief on the main boom beforehand. By doing this you prevent the
hose drum from twisting uncontrollably against the holder and the turning
hydraulic hoses injuring other people.
You must always insert the anti-twist device

before releasing the strain relief (1) from the
holder (2) on the main boom.
You may release the anti-twist device only af-

ter you have attached the strain relief (1) back
in the holder (2) on the main boom. 20.02.2001

There are eight bores (1) distributed over a the

radius on the inner flanged wheel (2) of the
hosedrum.
Inserting anti-twist device
• Turn the hose drum until a bore is in front of
the spring latch (3).
• Move the spring latch into the bore, the hose
drum is secured against twisting.
Removing anti-twist device
• Attach the strain relief on the main boom be-
fore removing.
• Withdraw spring latch (3) from the bore in
the flanged wheel.
Hydraulic Before operating the lattice extension, you must establish the hydraulic con-
connection nection. Before working with the main boom for longer periods, you must
disconnect the hydraulic connections.
G
Risk of accidents from hydraulic hoses springing back!
If you detach the strain relief after the anti-twist device has been released,
do not under any circumstances let go of the strain relief before it has been
re-attached. If you let go of the strain relief, the hydraulic hoses will spring
back uncontrolledly due to the spring force in the hose drum and may in-
jure persons or damage parts of the truck crane.
Position for working with the lattice

extension
• Take the strain relief out of the holder (1)

and pull the hydraulic hoses (2) towards the
main boom head.
• Hook the strain relief onto the holder (3).
• Guide the hydraulic hoses through the
guide rollers (4).
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Position for working with the main boom
• Remove the hydraulic hoses from the guide

rollers (4).
• Release the strain relief (2) on the holder (3)
and attach the strain relief to the holder (1).
20.02.2001

3.6.4 Folding the run-up rail out/in
The run-up rail is folded out for rigging and folded back in for on-road driv-
ing after derigging.
Folding out the run-up rail
• Unscrew the spring latch (2).

• Fold out the run-up rail (3) until the locking
bar (1) engages in the bore hole (4).
Folding in the run-up rail
• Pull the locking bar (1) downwards against

the spring force, and out of the bore hole (4).
• Fold out the run-up rail (3) to a small extent
and let go the locking bar (1).
• Fold in the run-up rail completely.
• Secure the run-up rail with the spring latch (2).
20.02.2001

3.6.5 Connections with folded lattice extension
The lattice extension is turned sideways to the main boom in the folded po-
sition.
In this position there are four areas on the main boom basic section, where
various connections have to be disconnected and reconnected again during
rigging and unrigging:
– in the front area (1), in front of the locking point at 100%,

– in the middle area (2), in front of the locking point at 50%,
– in the rear area (3), over the side panelling.
In each area there are bearing points that can be used for establishing con-
nections. Depending on the rigging mode and job, different parts of the lat-
tice extension must be connected to each other or connected to the main
boom basic section.
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.
20.02.2001

Connections in In the front area there is a connection between the 10 m section and the
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 disconnected when the lattice extension is being

rigged or removed.
The connection is made of retaining pins (3), slewing axle (1) at the basic
section and the holders (2) at the 10 m section.
For removing the connection, the 10 m section is derricked on the slewing
axle.
For establishing the connection, the 10 m section is locked in the slewing
axle and is secured with locking pins.
Securing the connection

• Swing the lattice extension on the run-up
rail onto the main boom until the bores (1)
on the 10 m section and the main boom are
aligned.
• Release the retaining pin and remove the
locking pin (2) from the holder (3).
• Insert the locking pin in the bore holes (1)
and secure it with a retaining pin.
G
Risk of accidents from a falling lattice extension.
The locking pin prevents mechanical pressing down of the slewing axle and
secures the 10 m section to the main boom. Therefore, always secure the
laterally folded lattice extension in the front area with the locking pin.
This will prevent the lattice extension (e.g. for main boom operation) from
sliding from the slewing axle and falling.
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Removing the connection
G
Before removing the connection ( à
p. 3 - 50) ensure that the 10 m section
is pinned on the main boom head.
This will prevent the lattice extension from falling and causing injury to you
or other persons.
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 be-
fore derricking out the lattice extension from the slewing axle.
This will prevent the lattice extension from slipping off the run-up rail,
swinging around and knocking you off the carrier or injuring other persons
in the slewing range.
• Secure the lattice extension with a guide rope; à p. 3 - 34.
• Remove the locking pin (4) from the bore

hole (3) and secure it in the holder (5) with a
retaining pin.
• Derrick the lattice extension fully on one of
the control units; à p. 3 - 69.
• Check, if the holder (2) on the 10 m section
is fully derricked downwards from the slew-
ing axle (1).
If the slewing axle is still parly in the holder,
then you must push it downwards mechani-
cally:
• Lift the lever (6) against the spring force and

hold it in the bracket (5).
During this, the slewing axle (1) is pressed
downwards.
• Swing the lattice extension outward until
the bracket (2) is no longer above the slew-
ing axle (1).
• Lift the lever sideways from the bracket and
slowly yield to the spring force. Once again
the slewing axle is pressed upwards.
With this, the connection is in the correct posi-
20.02.2001
tion for next unrigging.

Establishing a connection
• Place the lattice extension on the run-up rail.
• Check if the locking pin (4) is pulled out of
the bore hole (3).
• Check, if the lever (7) is under the bracket (6).
• Swing the lattice extension on the run-up
rail sideways onto the main boom.
First the slewing axle (1) is pressed down by
the holder (2) and then it is locked in the
holder.
• Check if the slewing axle projects upwards
from the bracket.
• Remove the locking pin (4) from the
holder (5), insert it in the bore holes (3) and
secure it with the retaining pin.
Connections in the When connecting in the middle area, three different joints can be estab-
middle area lished:
– 7 m section / 10 m section joint,

– 7 m section / main boom joint,
– Joint at the 10 m section
7 m section / 10 m section joint

This joint has to be established:
– when rigging the 17 m two-stage swing-away lattice extension –
before the lattice extension is swung onto the main boom head,
– when rigging the 17 m two-stage swing-away lattice extension –
after the 7 m section was folded onto the 10 m section,
– when rigging the 10 m swing-away lattice extension – after the 10 m
swing-away lattice extension was swung sideways onto the main boom,
– before removing the two-stage swing-away lattice extension.
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s
• Fasten the locking bar (1) with a pin (2) onto

the 10 m section and with a pin (3) onto the
7 m section.
• Secure both the pins, each with one retain-
ing pin.
7 m section / main boom joint

– when rigging the 10 m swing-away lattice
extension – before the lattice extension is
swung onto the main boom head,
– before removing – when only the 10 m sec-
tion is supposed to be removed.
• Fasten the locking bar (1) with a pin (3) onto

the 7 m section and with a pin (2) onto the
7 m section.
ing pin.
Joint at the 10 m section

– when rigging the 17 m two-stage swing-
away lattice extension. – before the 7 m sec-
tion is folded before 10 m section.
– Before operating with the 10 m swing-away
lattice extension, if the 7 m section is re-
moved.
• Fasten the locking bar (1) with a pin (2) and
(3) onto the 10 m section.
20.02.2001
ing pin.

Connections in the Connection between 7 m section and main boom

rear area
The connection must be made:
– when unrigging of the 17 m two-stage swing-away lattice extension,
– for operation with the 10 m swing-away lattice extension.
The connection must be removed:

– when rigging the 17 m two-stage swing-away lattice extension,
– for unrigging the 17 m two-stage swing-away lattice extension.
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 10 m section ( à
p. 3 - 53), before you remove the connec-
tion between the 7 m section and the main boom.
This will prevent the 7 m section from falling down when releasing the con-
nection.

pin (1) from the bearing point (3).
• Insert the pin in the retaining sheet (2) and
secure it with a retaining pin.
• 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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s
Connection between 10 m section and main boom
H
This connection does not apply to truck cranes that are supplied with an
17 m two-stage swing-away lattice extension.
This connection must be established if the 10 m swing-away lattice exten-

sion is folded in to the side during unrigging.
The connection must be removed before the 10 m swing-away lattice exten-

sion is swivelled onto the main boom head, when the 7 m section is unin-
stalled.
If the truck crane was delivered only with a 10 m swing-away lattice exten-
sion (without 7 m section), the connection between the 10 m section and the
main boom is established using a retaining strut with two pins.
G
Ensure that the connection in front area is established and is secured;
à p. 3 - 43.
This will prevent the 10 m section from falling down when releasing the
connection.
• Loosen the retaining pin and remove the

pins (3) from the bearing points (2).
• Remove the retaining strut.
• Stow the retaining strut and the pins with
the retaining pins for operation (e.g. in the
storage box).
Correct original position is reached, when the
connection in front area is established and is
secured; àp. 3 - 43.
• Put the retaining strut (1) onto the bearing
point (2) on the main boom and 10 m sec-
tion.
• Fasten the retaining strut with pins (3) and
secure the pin with retaining pins.
20.02.2001

3.6.6 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 extension
and are secured there with retaining pins.
G
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 ac-
cord and causing injury to you or other persons.
G
Ensure that the connection in the front area is established, before you re-
lease the connection on the right side of the main boom head. This will pre-
vent the lattice extension from falling and causing injury to you or other
persons.
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 has to be removed so that the lattice extension can be swiv-
elled onto the main boom side during unrigging.
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

swivelled onto the main boom when it is on the run-up rail during unrig-
ging.
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s
Establishing For these connections you will find are three short pins and one long pin in
connections holders on the fixed part of the 10 m section.
Connections on the right side
• Swing the lattice extension onto main boom

head, until the bearing points (1) and (4) are
in alignment.
• Remove the retaining pins and take the two
pins (2) and (5) out of the holders (3).
• Insert the two pins into the bearing points
(1) and (4) and secure them with retaining
pins.
Connection on the left side
• 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 (5).
• First, insert the pin (3) in the upper bearing
point (1).
• Then insert the long pin (4) into the bottom
bearing point (2). If the bearing points do not
align, you can take the weight off the bear-
ing points; à Relieving the load on bearing
points, p. 3 - 52.
• Use retaining pins to secure the pins in the
bearing points.
20.02.2001

Connections Secure the lattice extension with a guide rope before removing any connec-
remove tions.
Connections on the left side
• Remove the retaining pins from pins in the

bearing points (1) and (2).
• First hammer the pin (4) out of the lower
bearing point (2). If the pin cannot be ham-
mered out, you can unload it; à Relieving
the load on bearing points, p. 3 - 52
• You may then hammer the pin (3) out of the
upper bearing point (1).
• Insert both pins into the holders (5) and se-
cure them with retaining pins.
Connection on the right side
G
Ensure that the connection in the front area is established, before you re-
lease the connection on the right side. This will prevent the lattice extension
from falling and causing injury to you or other persons.
• Swing the lattice boom onto the main boom,

and establish the connection in the front
area; à p. 3 - 45.
• Remove the retaining pins from pins (2) and
(5) in the bearing points (1) and (4).
• Hammer the two pins out of the bearing
points.
• Insert both the pins (2) and (5) into the hold-
ers (3) and secure them with retaining pins.
20.02.2001

Relieving the load The dead weight of the lattice extension can cause the bearing points on the
on bearing points left side to be misaligned or the pins to get weighted which makes it impos-
sible to knock them out.
When establishing or disconnecting the con-

nections proceed as follows:
• Lower the lattice extension until it is on the

ground with the supports (1) (if necessary,
override the lifting limit switch).
• Continue to lower carefully until the con-
necting points (2) align or until the load has
been removed from the pins; à Derricking
20.02.2001

3.6.7 Pin connections on the latticeextension
The 10 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 re-
taining sheet on the upper boom.
G
retaining pins. This prevents unsecured pins from becoming loose, falling
out and causing injuries.
G
Risk of accident due to 7 m section swinging of its own accord.
Always secure the 7 m section with a guide rope before removing any con-
nections.
This will prevent the 7 m section from swinging around of its own accord
and causing injury to you or other persons.
G
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 main boom have
been made before you release the connection on the right side of the pivot
point. In this way, you prevent the 7 m section from falling when this con-
nection is released and causing injury to you or others.
Connection on the left side

The connection needs to be established after the 7 m section has been swiv-
elled in front of the 10 m section during rigging.
The connection needs to be removed so that the 7 m section can be folded

at the side of the 10 m section during unrigging.
Connection on the pivot point, on the right side

This connection must be established if the 10 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 10 m swing-away lattice extension

is rigged and the 7 m section is attached to the main boom.
20.02.2001
s
Connection on the • Swivel the 7 m section in front of the 10 m section until the bearing points
left side on the left side are in alignment. If necessary, you can unload the bearing
points in the same way, as in the case of pin connections on the main
boom; à Relieving the load on bearing points, p. 3 - 52.
• Loosen the retaining pins and remove the
pins from the retaining sheet (1).
(2) and (3) on the left side and secure the
pins with retaining pins.
• Remove the retaining pins and take pins out
of the bearing points (2) and (3) on the left
side.
• Insert both pins into the top of the retaining
sheet (1) and secure them with retaining
pins.
Connection on the Before removing this connection, the connections between the 7 m section
pivot point and the main boom in the rear area must be established ( à
p. 3 - 47) and
the connection in the middle area must be in position 7 m section / main boom
(à p. 3 - 47).

• Remove the retaining pins and pull the pins
(2) and (4) out of bearing points (3) and (5).
• Insert both pins into the retaining sheet (1)
and secure them with retaining pins.
• Remove the retaining pins and take the con-
ical pin (4) and another bolt (2) out of the re-
taining sheet (1).
(3) and (5), the conical pin (4) is designed for
the lower bearing point.
• Secure the pins using retaining pins.
H
20.02.2001
Always insert the conical pin in the lower bearing point, so that you can
knock it down while removing the connection.

3.6.8 Swinging the lattice extension onto the main boom head
This section describes slewing the lattice extension

– onto the main boom head when rigging and
– onto the main boom basic section when unrigging.
The lattice extension must be swung out of the transport position onto the
main boom head so that the 10 m section can be fastened to the right side
of the main boom head with pins.
Prerequisites – The lattice extension is in transport position when the lattice extension is
folded at the side; à Transport condition with lattice extension folded at the
side, p. 3 - 37.
– The required connections among the individual lattice extension sections
or the lattice extension sections and the main boom have been removed.
Swinging the
lattice extension
When swung, the lattice extension rolls on the run-up rail, turns around the
connection in the front area (2) and 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.
• When unrigging push the lattice extension onto the run-up rail until the
connection in the front area is ensured. Secure the connection with the re-
taining pins; à Securing the connection, p. 3 - 43.
20.02.2001

3.6.9 Swivelling the lattice extension when rigging
H
This section describes the swinging of the lattice extension during rigging.
If you want to swing the lattice extension for unrigging, proceed in the op-
posite order.
When rigging the 10 m swing-away lattice extension and the 17 m two-stage

swing-away lattice extension, you have to swing the 10 m section in front of
the main boom head.
When rigging the 17 m two-stage swing-away lattice extension, you must

also swing the 7 m section in front of the 10 m section.
G
Danger of accident due to lattice extension turning 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 ex-
tension with a guide rope from the ground.
Swinging the Prerequisites:

10 m section in
– The lattice extension has been swivelled onto the main boom head;
front of the main
boom
à Swinging the lattice extension onto the main boom head, p. 3 - 55.
– The 10 m section is fastened to the right side of the main boom head;
– The lattice extension is secured on the head of the 10 m section with a
guide rope; àSecuring lattice extension with cord, p. 3 - 34.
• Disconnect the connection between the 10 m section and the main boom;
à Removing the connection, p. 3 - 44.
• Swing the lattice extension until it is no longer above the run-up rail.
20.02.2001

• Carefully lower the lattice extension from the control unit on the foot of
the 10 m section until it starts to swing out.
If a helper is holding the guide rope, he can now swing the lattice extension
in front of the main boom head.
If you are alone and when securing you fixed the guide rope to the crane,
the lattice extension turns only so far until the guide rope is taught. You can
now turn the lattice extension with the guide rope in front of the main boom
head.
Proceed in the opposite order for unrigging.
Swing the 7 m sec- Prerequisites:

tion in front of the
10 m section
– The 10 m section is locked in front of the main boom head; à Establishing
connections, p. 3 - 50.
– The lattice extension is secured on the head of the 7 m section with a
guide rope;
• Move the connection in the on 10 m section middle area; à Joint at the 10

m section, p. 3 - 46.
• Turn the 7 m section using the guide rope in front of the
the 10 m section.
Proceed in the opposite order for unrigging.

20.02.2001

3.6.10 Electrical connections on the lattice extension
The SLI, the lifting limit switch and the lowering limit switch are connected
via the electrical connection on the lattice extension.
10 m swing-away For the 10 m swing-away lattice extension the electrical connection is made
lattice extension or disconnected on the right side of the main boom head.
Establishing the 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.
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 10 m section.
dummy socket (5) and plug it in the socket
(4) on the main boom.
• Wind the cable onto the take-up reel (6).
20.02.2001

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

the socket (1) at the front of the 10 m section.
17 m two-stage For the 17 m swing-away lattice extension an additional connection is made

swing-away lat- or disconnected between the 10 m section and the 7 m section as well as the
tice extension electrical connection of the 10 m swing-away lattice extension.
• First make the electrical connection for the 10 m swing-away lattice exten-
sion; à p. 3 - 58.
Establishing the 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 socket
(4) on the 10 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
10 m section.
20.02.2001

Disconnecting electrical connection
• Remove the plug (3) from the socket (4) on

the 10 m section.
• Remove the dummy plug (2) from the
dummy socket (1) on the 7 m section and in-
sert it in the socket (4) on the 10 m section.
• Insert the plug (3) in the dummy socket on
the 7 m section.
• Wind the cable onto the take-up reel (5).
3.6.11 Establishing/disconnecting the hydraulic connection
The hydraulic supply is required for derricking the lattice extension. Before
establishing the connection, the connections on the hose drum must be in
the working with the lattice extension position; à
Hose drum for hydraulic supply,
p. 3 - 38.
S
Risk of damage to hydraulic hoses!
When establishing the connection, always move the hoses right out of the
10 m section. If the hoses are moved out of the front of the 10 m section,
they will be damaged if the lattice extension turns.
Establishing the hydraulic connection

• Take the hose line (2) out of the holders (3)
on the 10 m section and remove the
protective cap.
• Pull the hose lines right out of the 10 m
section and guide the hose lines to the left
side of the main boom head.
• Remove the protective caps from the quick
couplings (1) and connect the hose lines
there (observe colour code).
20.02.2001

Remove the hydraulic connection

• Remove the hose pipes (2) from the quick
couplings (1) on the main boom head.
• Seal the quick couplings with the protective
caps.
• Squeeze the hose pipes into the holders (3)
on the 10 m section.
• Close the hose ends with the protective
caps.
3.6.12 Folding out / in the deflection sheaves on the 10 m section
To prevent the hoist rope dragging on the main boom or lattice extension
during operation with the lattice extension or boom extension, the hoist
rope is guided via deflection sheaves.
On the 10 m section there is a deflection

sheave at the rear (1) and a deflection sheave
at the front (2).
Both sheaves must be folded out:

– for operation with the 10 m swing-away lat-
tice extension,
– for operation with the 17 m two-stage
For transportation both deflection sheaves
must be folded in.
20.02.2001
s
Folding rear de-
G
flection sheave
Risk of crushing.
Always hold the deflection sheave by the handle, when removing the pin.
You might get your fingers crushed if you hold the sheave by the side plate.
Folding out deflection sheave
• Hold the deflection sheave by the handle (2)

and remove the pin (3) from the bore (1).
• Fold the deflection sheave up and secure it
with the pin in the bore (4).
• Secure the pin with a retaining pin.
Folding in deflection sheave
• Hold the deflection sheave by the handle (2)

• Fold the deflection sheave down and insert
the pin in the bore (1).
20.02.2001

Folding front de-
G
flection sheave
Risk of crushing.
Always hold the deflection sheave by thestrut on the top when removing
the pin. You might get your fingers crushed if you hold the sheave by the
side plate.

• Unscrew the retaining pin on the pin (3).
• Hold the deflection sheave by the strut (1)
• Fold the deflection sheave up until the pin
can be inserted through the bore (2) again.
• Insert the pin through the bore and secure it
with a retaining pin.

• Unscrew the retaining pin on the pin (3).
• Fold the deflection sheave down until the
pin can be inserted through the bore (2)
again.
• Insert the pin through the bore and secure it
20.02.2001

3.6.13 Positioning/removing the hoist cable
G
Always secure the hoist cable holding rollers and rods with retaining pins.
This prevents elements from coming loose, falling down and injuring
people.


Positioning • Remove the hoist cable holding rollers and rods (1).
hoist cable
• Guide the hoist rope via the deflection sheaves (4), (3) and via the head
sheave (2) on the 10 m section or on the 7 m section.
• Put all hoist cable holding rollers and rods back in place and secure these
with retaining pins.
• 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;
à p. 3 - 65.
Removing • Unreeve the hook block.

hoist 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
20.02.2001

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

methods on the
lattice extension
Hook tackle, max. lifting capacity: 8 t
maximum load bearing capacity with GMK 4075: 1 fall

Single reeving 5 t (11,000 lbs)
1-sheave hook block, max. load bearing capacity 1 fall 2 fall

20 t
maximum load bearing capacity with GMK 4075:

for simple reeving 5 t (11,000 lbs)
for two falls reeving 10 t (22,000 lbs)
The hoist rope can be reeved a maximum of two falls on the 10 m swing-
away lattice extension.
On the 17 m two-stage swing-away lattice extension and on the 22/27m

boom extension the hoist cable can only be reeved once.
Reeving the hoist rope in the hook block; à Operating instructions GMK
4075, Part 2 Superstructure – Rigging work main boom.
• Fasten with a 2-fall reeving, the rope end clamp on the attachment plate
(1), in front on 10 m section..
20.02.2001

3.6.14 Lifting limit switch on the lattice extension
The functions raise hoist, 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 lifting limit switch is actu-
ated.
H
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.
On 10 m swing-
away lattice
extension
• Attach the lifting limit switch (4) in the
holder (5) and secure it with a retaining pin.
socket (1).
• Connect the lifting limit switch on the socket
(1).
• When unrigging you must insert the short-

circuit plug (2) back in the socket (1).
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On the 17 m two-
stage swing-away
lattice extension
H
For operation with the 17 m two-stage swing-away lattice extension the
connection for the lifting limit switch on the 10 m section must be overrid-
den with a short-circuit plug.
• Attach 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.
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3.6.15 Anemometer on the lattice extension
H
The same anemometer is used for lattice extension and main boom.
On 10 m swing-
away lattice
extension
• Attach the anemometer (3) to the holder (2)
on the head of the 10 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 10 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 dis-
tribution box with the protective cap.
On the 17 m two-
stage swing-away
lattice extension
• Attach the anemometer (1) to the holder (2)
on the head of the 7 m section and secure it
• 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 dis-
tribution box with the protective cap.
20.02.2001
H
You must remove the anemometer before unrigging the lattice extension.

3.6.16 Derricking the lattice extension
Before derricking the lattice extension set an SLI rigging code or a SLI code
for work with the lattice extension.
When rigging To derrick the lattice extension when rigging there are two control units
each with two pushbuttons on the 10 m section.
• To raise press the top push-button raise lat-

tice extension (1).
• To lower press the bottom push-button
lower lattice extension (2).
During operation During operation the lattice extension is derricked from the crane cab.
The lattice extension can be derricked, only when the derricking gear for the
lattice extension is switched on.
When the derricking gear is switched on:
z – the indicator lamp in the rocker switch derricking lattice extension on / off
lights up brightly and
= – is shown on the display crane control and in the main menu the indicator
lamp derricking lattice extension on / off lights up green.
• If necessary, switch on the derricking gear of the lattice extension, for this
z once press the rocker switch derricking lattice extension on / off.
To raise press the right control lever to the left.
To lower press the right control lever to the right.

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3.6.17 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 capacity.
This prevents the lattice extension from falling and injuring people while
loading; àCentres of gravity for slinging, p. 3 - 8.
• Check if all the required connections for transport condition are estab-
lished; à Transport condition with removed lattice extension, p. 3 - 37.
• 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 10 m
section.
• Always secure the lattice extension on the
separate vehicle with belts as well to pre-
vent slipping and overturning.
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 trans-
portation.
20.02.2001

3.7 Raising and setting down the main boom with rigged lattice extension
3.7 Raising and setting down the main boom with rigged
lattice extension
H
The information in this section also applies for raising and setting down the
main boom with a rigged boom extension.
H
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.
For raising and lowering, the following prerequisites must be fulfiled:
– The SLI code for the actual rigging mode is set on the SLI with
00== the rigged lattice extension; à Operating instructions GMK 4075,
Part 2 Superstructure – Crane operation.
– The current reeving of the hoist cable on the lattice extension is entered.
! – Apart from the hook block there is no load on the lattice extension.
• Derrick in the main boom to raise.

• Derrick out the main boom to set down.
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3.7 Raising and setting down the main boom with rigged lattice extension
Blank page
20.02.2001

3.8 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 ex-
tension, you must not rotate the superstructure at the same time.
This prevents the main boom being subjected to additional side forces and
increased vibration and becoming overloaded.
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 in the rigging programs.
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 de-
pends on the length of the lattice extension ( à
Rigging programs in the lifting
capacity table).
If the main boom angle is too small for telescoping with the rigged lattice
extension angle, the SLI shows the corresponding error message.
• Set down the load.

• Derrick in the main boom by the appropriate angle according to the rig-
ging program ( à 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.
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20.02.2001

3.9 Operation with the lattice extension
H
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!
No hook block may be reeved on the main boom during operation with the
boom extension.
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 lattice
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 entered in
their own table in the lifting capacity tables.
H
The hoisting, lowering, slewing, derricking and telescoping movements 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 value à
Rigging programs in the lifting
capacity table).
3.9.1 SLI shutdown
The operation with the lattice extension and the boom extension is moni-
tored by the SLI.
SLI shutdowns can occur during lattice extension operation for the same
reasons as with main boom operation; à
Operating instructions GMK 4075,
Part 2 – Crane operation.
If you have entered a SLI code for a lifting capacity table with a certain angle
of the lattice extension, SLI releases the given load only then, when the lat-
tice extension is derricked to this angle in advance.
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3.9.2 Procedure if the permissible wind speed is exceeded
Strong winds can overstrain the truck crane. Therefore, closely observe the
instructions in the Effect of wind on crane operation, à
Operating instructions
GMK 4075, Part 2 – Crane operation.
If the maximum permissible wind speed according to the lifting capacity

table is exceeded during the main boom operation,
proceed as follows:
with wind speed with wind speed
up to 20 m/s over 20 m/s
• Set down the load. • Set down the load.
• Slew the superstructure so that • Fully retract the main boom.
the main boom creates as little • Set down the lattice extension.
wind resistance as possible.
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3.10 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 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 individ-
ual parts of the truck crane being overloaded. The SLI then no longer pro-
vides protection.
Two-hook operation with the boom extension is not permitted!
G
The load must always be lifted completely with the weakest part first (lattice
extension).
H
You can find the position and function of the required operating instru-
ments in the supplied Operating instructions of the GMK 4075.
3.10.1 Prerequisites
The following description requires that:
– the main hoist cable is reeved on the main boom

– the auxiliary hoist rope is reeved on the lattice extension and
– the lifting limit switches for both hoists are connected.
G
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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3.10.2 Setting SLI
For two-hook operation, both hoists must be activated on the SLI.
H
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 elimi-
nates the need for input later during operation. Proceed as follows:
• Switch off both hoists.

äå For this, press down once both the rocker switches main hoist on/off and
auxiliary hoist on/off.
Indicator lamps in the rocker switches are dimly illuminated.
32 When the main hoists are switched off, the main hoist on/off indicator lamp in
the main menu on the crane control and auxiliary hoist on/off display lights up
red.
• Switch on the main hoist.

ä Additionally, press the main hoist on/off rocker switch down once. The indi-
cator lamp in the rocker switch lights up brightly.
Lamp I for the main hoist lights up in the Hoists indicator lamps.
• In the display reeving , enter the quantity of reeved cable of the main hoist
§ cable on the main boom.
Now the reeving for the main hoist is stored and you can switch to the aux-
iliary hoist.

• Switch on the auxiliary hoist.

å Additionally, press the auxiliary hoist on/off rocker switch down once. The
indicator lamp in the rocker switch lights up brightly.
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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
4 hoist rope of the lattice extension.
Now the reeving for the auxiliary hoist is also stored and you can switch on
the main hoist.
ä Switch on the main hoist.

Additionally, press the main hoist on/off rocker switch down once. The indica-
tor lamp in the rocker switch lights up brightly.
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.
Now the SLI is set for two-hook operation; this takes into account the reev-
ing for the auxiliary hoist and the lifting capacity table for the lattice exten-
sion.
H
In two-hook operation the loads given in the lifting capacity table are reduced
by the weight of both reeved hook blocks.
20.02.2001
s
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.
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 SLI
shutdown.
H
As long as the load is hanging on two hooks, you may not switch the SLI
code to operation with the main boom. It must be set to operation with the heavy
load lattice extension during the entire lifiting procedure.
C0183
• Lift the load fully with the lattice extension.

• Only now should you attach the load to the hook block of the main boom
as well.
• Now lift the load with the hook block on the main boom until both slinging
points are at the same height.
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C0184
• Slacken the hoist cable on the lattice extension until the load is only hang-
ing from the hook block on the main boom.
Turning the load is thus completed.
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20.02.2001

3.11 Driving with rigged crane and installed lattice extension
3.11 Driving with rigged crane and installed lattice

extension
This section describes how you can move the truck crane with an installed
counterweight and rigged lattice extension (e.g. when the lattice extension
cannot be rigged on the site due to lack of space).
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.
3.11.1 Driving route
The route must be a flat, even surface. The level adjustment system cannot
compensate for uneven surfaces. If the surface pressure of the tyres ex-
ceeds the permissible load on the ground, the surface pressure must be in-
creased using packing made of durable material (e.g. wooden planks).
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; à Operating instructions GMK 4075, Part 1 Carrier – Technical data.
Do not reduce the tyre pressure!
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3.11.2 Boom positions and axle loads
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 indica-
11== tor. The SLI code 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
Risk of accidents if SLI is overridden.
Always set the SLI rigging code corresponding to the current rigging mode
when you derrick the main boom into the prescribed position. Do not over-
ride the SLI; the prescribed positions in the following tables are all within
the areas which are permitted according to the lifting capacity tables.
The truck crane safe load indicator does not function when the SLI is over-
ridden!
20.02.2001

10 m swing-away The following table only applies if the 11 m swing-away lattice extension is
lattice extension rigged.
Tables for rigged 17 m two-stage swing-away lattice extension; p. 3 - 86. à
Tables for rigged boom extension; à
p. 4 - 25.
H
The axle loads specified in the following tables refer to a driving mode with
the basic unit and 16 t hook tackle reeved on the lattice extension, hook
blocks must be unreeved.
Coun- Telescoping Main Lattice Main 2) Axle load 2)Axle load

ter- Telescope boom exten- main in t x 1000 lbs
weight section angle in ° sion an- boom
in t I/II/III/IV gle in ° position1 at the rear at the rear
) front front
0/0/0/0 15 5 front 12.0 12.0 26.5 26.5

9.13)
0/0/0/0 70 5 rear 12.0 12.0 26.5 26.5
0/0/0/0 15 5 front 11.5 13.0 25.5 29.0
10.1
0/0/0/0 70 5 rear 12.5 12.0 27.5 26.5
0/0/0/0 15 5 front 11.0 14.5 24.5 32.0
12.1
0/0/0/0 70 5 rear 13.5 12.0 30.0 26.5
0/0/0/0 15 5 front 9.5 18.0 21.0 40.0
16.1
0/0/0/0 70 5 rear 15.0 12.5 33.0 27,5
1)Boom position to the rear: 0° position, boom over

Truck crane rear edge
Boom position at the front: 180° position, boom over driver's cab
2)Axle load front: Each time on the first and the second axle
line
Axle load rear: Each time on the third and the fourth axle
line
3)The counterweight version 9.1 t is additional equipment
20.02.2001
s
17 m two-stage The following table only applies if the 17 m two-stage swing-away lattice ex-
swing-away lat- tension is rigged.
tice extension Tables for rigged 10 m two-stage swing-away lattice extension; p. 3 - 85.à
Tables for rigged boom extension; à
p. 4 - 26.
H
Coun- Telescoping Main Lattice Main 2) Axle load 2)Axle load

ter- Telescope boom exten- main in t x 1000 lbs
weight section angle in ° sion an- boom
in t I/II/III/IV gle in ° position1 at the rear at the rear
) front front
0/0/0/0 15 5 front 12.5 11.5 27.5 25.5

9.13)
0/0/0/0 70 5 rear 11.5 12.5 25.5 27.5
0/0/0/0 15 5 front 12.5 12.5 27.5 27.5
10.1
0/0/0/0 70 5 rear 12.0 12.5 26.5 27.5
0/0/0/0 15 5 front 11.5 14.0 25.5 31.0
12.1
0/0/0/0 70 5 rear 13.0 12.5 29.0 27.5
0/0/0/0 15 5 front 13.0 17.5 23.5 38.5
16.1
0/0/0/0 70 5 rear 15.0 13.0 33.0 29.0
1)Boom position to the rear: 0° position, boom over

Truck crane rear edge
line
line
3.11.3 Driving the rigged crane
Locking the super- Before the truck crane is moved, the superstructure must be locked to the
20.02.2001
structure and carrier; à Operating instructions GMK 4075, Part 2 Superstructure – Crane op-
engaging the eration.
slewing gear
permanent brake

• Lock the superstructure, the lever must point to the left.
H
During the following work, you must temporarily switch on and switch off
the suspension locking system, which is possible only in the driver's cab. It
is therefore recommended to carry out the flowing work from the carrier.
Retracting the • Retract the outrigger cylinders until the wheels are just above the ground.
G
outrigger
Make sure that the truck crane does not overturn when the outriggers are
being retracted.
Retract all the outrigger cylinders as uniformly as possible.
Switching over
the suspension
locking system
• Switch the suspension locking system off. To do this push up the suspen-
u sion locking system rocker switch in driver's cab. The suspension locking sys-
tem indicator lamp must extinguish.
• 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 sys-
tem indicator lamp lights up when the suspension system is locked.
• Continue to retract the outrigger cylinders.
G
#
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.
20.02.2001
s
Switching on Before driving with the rigged crane you must switch on separate steering:
S
separate steering
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 stationary
the steering linkage may become damaged.
If you drive the truck crane from the driver's cab:

• Switch on the level adjustment system key switch.
C0018
• Switch on separate steering by releasing the separate steering rocker switch

b and pressing it down.
? The warning lamp steering unlocked illuminates when the steering is un-
locked.
• Turn the third axle line with separate steering rocker switch, until the third
b and fourth axle lines have the same steering angle.
The connection between the 3rd and 4th axle lines snaps audibly into place
and the wheels of the 3rd and 4th axle lines move together.
The steering system is now switched to all-wheel steering.
If you drive the truck crane from the crane cabin:
• Press the release separate steering rocker switch downward.

b This requires pressing the lock button downward.
? The warning lamp steering unlockedilluminates when the steering is un-

locked.
• Turn the third axle line with separate steering rocker switch in the laft-hand
control lever, until the third and fourth axle lines have the same steering
angle.
The connection between the 3rd and 4th axle lines snaps audibly into place
20.02.2001
and the wheels of the 3rd and 4th axle lines move together.
The steering system is now switched to all-wheel steering.

S
Driving
levels à Operating instructions GMK 4075, Part 1 Carrier – Technical data.
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 truck crane; à
Operating instructions GMK 4075, Part 2 Superstructure –
Crane operation.
• From the crane cabin switch to driving mode with a load before driving to
3 keep the speed to a minimum. To do this, press down the rocker switch
driving with a load; à Operating instructions GMK 4075, Part 2 Superstruc-
ture – Crane operation – Driving the truck crane from the crane cabin.
• Before driving, switch to the starting gear from the driver's cab and switch
to manual after starting, whereby you push the switch lever gears once to
the left.
This prevents upshifting of the gears and the speed is kept to a minimum;
à Operating instructions GMK 4075, Part 1 Carrier – Driving the truck crane.
Please observe the following points while driving:

• Drive only with a minimum 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.
If the ground is uneven, use the outrigger cylinders to raise the truck crane,
level it horizontally and lower it again; à
Operating instructions GMK 4075,
Part 2 Superstructure – Rigging and Part 1 Carrier – Driving the truck crane.
Extending the Before starting with the crane work, it must be rigged; à Operating instruc-
outrigger tions GMK 4075, Part 2 Superstructure – Rigging work.
G
The truck crane must be raised until no wheels touch the ground.
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3.12 Malfunction when working with lattice extension
H
The information in the following table applies to malfunctions during oper-
ation with the 10/17 m lattice exension as well as to operation with the
22 / 27 m boom extension.
Malfunction Cause Remedy

No function of the lifting limit Lifting limit switch not con- Connect the lifting limit
switch nected switch; à Lifting limit switch
on the lattice extension, p. 3 - 66.
Electrical connection between Establishing electrical con-
the boom head and lattice ex- nection; à 10 m swing-away
tension and between 10 m lattice extension, p. 3 - 58.
section and 7 m section is not
established
Lifting limit switch on the Override the lifting limit
main boom head not overrid- switch on the main boom
den head; à p. 3 - 66.
When operating with an 17 m Insert short-circuit plug;
lattice extension or boom ex- à p. 3 - 59.
tension the short-circuit plug
is not inserted on the head of
the 12.5 m section.
The main boom cannot be The main boom is derricked to Derrick the main boom to the
telescoped with the rigged such an angle at which tele- required angle;
lattice extension or boom ex-
tension
scoping is not permissible à Telescoping with rigged lat-
tice extension, p. 3 - 73.
The lattice extension cannot Derricking gear of the lattice Switch on the derricking gear
be derricked extension is switched off of the lattice extension; à At
the control console right, p. 3 - 2.
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20.02.2001

3.13 Maintenance work
3.13.1 Modules in need of protection during cleaning work
• Provide protection for the following electrical parts during cleaning work:
– potentiometer in the joint (1) of the 10 m section
– the control box at the rear of the 10 m section (2),
– the control box at the front of the 10 m section (3),
– the control box at the front of the 7 m section (4)
– both the control units (5).
H
Also observe all instructions contained in the chapter titled Cleaning work of
the Maintenance manual.
20.02.2001

3.13.2 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; à
Maintenance
manual GMK 4075 Maintenance overview – Maintenance Plan M1.
Pins Lubricate all attach, securing and retaining pins, in other words
– the pins for the pin connection on the lattice extension,

– the retaining pins on the return pulleys,
– the retaining pins used for fastening the lattice extension sections for
transport,
– the spring latch on the run-up rail.
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.
Support rollers There are two support rollers on the lattice extension that need to be lubri-
cated.
The two support rollers (1) and (2) are on the

bottom of the 10 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.
20.02.2001

Lubricating joint The joints are lubricated via lubricating nipples.

on 10 m section
On either side of 10 m section, there is a lubri-

cating nipple at the (1) pivot point.
• Clean the lubricating nipple and lubricate it

with a grease gun.
• Also lubricate the joint on the other side.
Lubricate the der- The derricking cylinder is lubricated via a lubricating nipple.
ricking cylinder in
10 m section
On the head and foot axle there is one lubricat-

ing nipple each (1).
• Clean the lubricating nipple and lubricate it

with a grease gun.
20.02.2001

Blank page
20.02.2001

4
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 Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5

4.3.1 CHECK LIST: Rigging the 22 m/27 m boom extension . . . . . . . . . . . . . . . . . . . . 4 - 5
4.3.2 CHECK LIST: Unrigging the 22 m/27 m boom extension . . . . . . . . . . . . . . . . . . 4 - 9
4.4 Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
4.4.1 Installing/removing 5 m sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
4.4.2 Installing/removing the two-stage swing-away lattice extension for the
boom extension 4- 14
4.4.3 Hydraulic connection at the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
4.4.4 Electrical connection at the boom extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 18
4.4.5 Unfolding/folding the deflection sheave on the 5 m section . . . . . . . . . . . . . . . 4- 20
4.4.6 Positioning/removing the hoist cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 21
4.5 Driving with rigged crane and rigged boom extension . . . . . . . . . . . . . . . . . . . . . 4 - 23
4.5.1 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
4.5.2 Boom positions and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
4.5.3 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
4.6 Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
4.6.1 Maintenance work M1, monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
16.02.2001

16.02.2001

Boom extension (additional equipment)
4.1 Identification and slinging points
4 Boom extension (additional equipment)
4.1.1 Identification
The boom extension consists of the 17 m two-stage swing-away lattice ex-

tension and two boom extension sections. The boom extension is designed
for the truck crane it was delivered with. The parts which belong to the truck
crane have the same serial number as the truck crane.
The following sections are identified by the serial number:
– All parts of the 17 m two-stage swing-away lattice extension; à p. 3 - 5.

– Both sections of the boom extension (5 m sections).
S
Operate the truck crane only with those sections of the boom extension
which have the same serial number as the crane.
The SLI is only set for this boom extension.
This prevents malfunctions and damage.
H
For technical reasons a truck crane may only be set with one boom exten-
sion.
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 labelled
with all of the respective serial numbers.
S
Have the adjustment of the boom extension only carried out on site by
GROVE Customer Support!
20.02.2001
s
Serial numbers on the 5 m sections
The serial number (1) is on a sheet at the front

of the 5 m sections.
4.1.2 Slinging points
G
This section shows the slinging points of the 5 m sections.
Attach the sections only to these slinging points because they will then
automatically have the correct centre of gravity. Use only lifting gear with
sufficient load bearing capacity; à Transport dimensions and weights,
p. 2 - 1.
The 5 m sections have two slinging points (1)

(one slightly offset on each side).
20.02.2001

4.2 Assembly of boom extensions
22 m boom extension
(85 ft boom extension)
5 m section 10 m section 7 m section

(16 ft section) (33 ft section) (23 ft section)
27 m boom extension
5 m section 5 m section 10 m section 7 m section

(16 ft section) (16 ft section) (33 ft section) (23 ft section)
H
The lengths of 22 m and 27 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 10 m section, 7 m section and 5 m section have been ad-
justed to these lengths. The total length of the individual sections is greater
or smaller; à Transport dimensions and weights, p. 2 - 1.
20.02.2001

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20.02.2001

4.3.1 CHECK LIST: Rigging the 22 m/27 m boom extension
H
Observe the warning and safety information given there!
Prerequisites:
support.
ging, p. 3 - 33.
2. If the lattice extension is folded up at the side of the main boom, re-
move the lattice extension; à
CHECK LIST: Uninstalling (two-stage)
swing-away lattice extension, p. 3 - 12.
4. Check the transport condition of the two-stage swing-away lattice

extension; àTransport condition with removed lattice extension, p. 3 - 37.
5. Install 5 m sections in front of the main boom:

One 5 m section for the 22 m boom extension,
Both 5 m sections for the 27 m boom extension
à Slinging points, p. 4 - 2.
à Installing/removing 5 m sections, p. 4 - 13.
20.02.2001
s
6. Sling two-stage swing-away lattice extension on auxiliary crane;

7. Install folded two-stage swing-away lattice extension in front of the

5 m section; à Installing/removing the two-stage swing-away lattice exten-
sion for the boom extension, p. 4 - 14.
9. Move the connection in the middle area on 10 m section; à Joint at the 10

m section, p. 3 - 46.

11. Fasten the 7 m section on left-hand side in front of 10 m section with a

pin; à Pin connections on the latticeextension, p. 3 - 53.
20.02.2001

12. Establish a hydraulic connection; à Hydraulic connection at the boom ex-

tension, p. 4 - 15.
13. Establish electrical connections; à Electrical connection at the boom ex-

tension, p. 4 - 18.
14. Fold out deflection sheaves of all sections;

à Folding out / in the deflection sheaves on the 10 m section, p. 3 - 61.
à Unfolding/folding the deflection sheave on the 5 m section, p. 4 - 20.
15. Place hoist rope on all deflection sheaves and the head sheave of the
7 m section; à Positioning/removing the hoist cable, p. 4 - 21.
p. 3 - 66.
20.02.2001
s
weight; àOperating instructions GMK 4075, Part 2 Superstructure –
Rigging work.
20. SLI code according to the Lifting capacity table for the actual rigging
00== mode of the truck crane with the 22 m or 27 m boom extension.
Set rigging mode à Operating instructions GMK 4075, Part 2 Superstruc-
ture – Crane operation.
H
Operation with the boom extension is carried out in the same way as
for the lattice extension.
Raising the boom; à p. 3 - 71,
Telescoping; à p. 3 - 73,
SLI shutdown; à p. 3 - 75.
20.02.2001

4.3.2 CHECK LIST: Unrigging the 22 m/27 m boom extension
H
Observe the warning and safety instructions given there!
Prerequisites:
support.
ging, p. 3 - 33.
2. Fully retract and set down the main boom.
3. Enter SLI code according to the Lifting capacity table for the actual rig-
00== ging mode of the truck crane with the rigged boom extension.
Set rigging mode à
Operating instructionsGMK 4075 part 2, Superstruc-
ture – Crane operation.
à Lifting limit switch on the lattice extension, p. 3 - 66.
p. 3 - 65.

20.02.2001
s

p. 3 - 69.
8. Detach the hydraulic connection; à Hydraulic connection at the boom ex-

tension, p. 4 - 15.
9. Detach electrical connections; à Electrical connection at the boom exten-

sion, p. 4 - 18.
10. Remove hoist rope and fold in deflection sheaves on all parts of the
boom extension; à Positioning/removing the hoist cable, p. 4 - 21.
à Folding out / in the deflection sheaves on the 10 m section, p. 3 - 61.
à Unfolding/folding the deflection sheave on the 5 m section, p. 4 - 20.

20.02.2001

13. Remove the locking pins on the left-hand side between 7 m section and
10 m section; à
Pin connections on the latticeextension, p. 3 - 53.

15. Position the central area of the connection 7 m section / 10 m section posi-
tion,; à 7 m section / 10 m section joint, p. 3 - 45.
16. Sling two-stage swing-away lattice extension on auxiliary crane;

17. Remove folded two-stage swing-away lattice extension from the

5 m section; à Installing/removing the two-stage swing-away lattice exten-
sion for the boom extension, p. 4 - 14.
18. Remove 5 m sections from the main boom:

One 5 m section for a 22 m boom extension,
Both 5 m sections for a 27 m boom extension
à Slinging points, p. 4 - 2.
à Installing/removing 5 m sections, p. 4 - 13.
20.02.2001
s

20.02.2001

4.4.1 Installing/removing 5 m sections
– In order to rig the 22 mboom extension you must install the 5 m section
with support roller in front of the main boom head.
– In order to rig the 27 m boom extension you must additionally
install the 5 m section without support roller in front of the 5 m section
with support roller.
H
An auxiliary crane must be used to install and remove the 5 m sections.
The securing pins (1) for the connection are se-

cured with retaining pins in the holders at the
foot of the 5 m sections.
Installing 5 m sections
• Sling the 5 m section with support roller 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.
• Insert the securing pins into the bearing
points (2) and (3) on both sides.
• Secure all pins with retaining
needles.
• Install the second 5 m section in front of the
first 5 m section for the 27 m boom exten-
sion in the same way.
Removing 5 m sections
• Sling the 5 m section on an auxiliary crane and lift it until the bearing
points (2) and (3) are relieved.
• Release the pins and knock them out of the bearing points (2) and (3) on
both sides.
20.02.2001
• Insert the pins into the holders at the foot of the 5 m sections and
secure them with retaining needles.

4.4.2 Installing/removing the two-stage swing-away lattice

extension for the boom extension
This section describes the installation and removal of the folded two-stage
You can also install the folded two-stage swing-away lattice
extension in front of a 5 m section (e. g. when you are changing directly
from the 17 m two-stage swing-away lattice extension to a boom exten-
sion).
H
An auxiliary crane is required to install and remove the two-stage swing-
away lattice extension.
The securing pins (1) for the connection are in

the holders at the foot of the 10 m sections and
are secured with retaining needles.
Installation
• Sling the two-stage swing-away lattice ex-
tension onto an auxiliary crane; à Centres
of gravity for slinging, p. 3 - 8.
• Lift the two-stage swing-away lattice exten-
sion in front of the 5 m section so that the
bearing points (2) and (3) align on both
sides.
• Insert the securing pins into the bearing
points (2) and (3) on both sides.
• Secure all pins with retaining needles.
Removal
• Sling the two-stage swing-away lattice extension onto an auxiliary crane;
• Lift the two-stage swing-away lattice extension until the bearing points
are relieved.
• 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 10 m section and secure them with
retaining needles.
20.02.2001

4.4.3 Hydraulic connection at the boom extension
The hydraulic supply is required for derricking the lattice extension. You
must re-establish the hydraulic connection of the hose drum if it has been
detached in order to work with the main boom; à
Hose drum for hydraulic
supply, p. 3 - 38.
Transport condi- For transport, bring the hydraulic connections always into the following
tion of the connec- condition.
tions
The hydraulic hoses (5) are in the 5 m section

with deflection sheave. For transport, the hy-
draulic hoses are clamped in the holders (3).
At the two front hose ends there are two quick-

action couplings (4) that are attached to a
sheet (1). For transport, the sheet is attached in
the holder (2) at the front.
The quick-action couplings (1) are at the rear

hose ends (3).
For transport, the hydraulic hoses are clamped
in the holders (2).
20.02.2001
s
At the 22 m boom All connections are made via quick-action couplings. Half couplings which
extension belong together are colour coded.
• Connect the rear hose ends (1) of the 5 m section to the quick-action cou-
plings (2) at the main boom head.
• Connect the hydraulic hoses (3) of the 10 m section to the quick-action
couplings (4) of the 5 m section at the front.
Disconnecting
• Disconnect all the quick-action couplings and cover them with protective
caps.
• Make the connections ready for transport; à p. 4 - 15.
20.02.2001

At the 27 m boom All connections are made via quick-action couplings. Half couplings which
extension belong together are colour coded.
• Connect the rear hose ends (1) of the 5 m section to the quick-action cou-
plings (2) at the main boom head.
• Detach the hydraulic hose (3) from the holders (4) in the 5 m section with
deflection sheave.
• Remove the sheet (6) from the holder (5) and pull the hydraulic hoses
through the front 5 m section.
• Attach the sheet (6) in the holder (9) and clamp the hydraulic hoses into
the holders (10) in the front 5 m section.
• Connect the hydraulic hoses (7) of the 10 m section to the quick-action
couplings (8) of the 5 m section at the front.
Disconnecting
• Disconnect all the quick-action couplings and cover them with protective
caps.
• Make the connections of the 5 m sections ready for transport; à p. 4 - 15.
• Clamp the connections of the 10 m section to the holders at the
10 m section; à p. 3 - 61.
20.02.2001

4.4.4 Electrical connection at the boom extension
This section only describes the electrical connections at the 5 m sections.

For establishing the electrical connection at the two-stage swing-away lat-
tice extension; à Electrical connections on the lattice extension, p. 3 - 58.
Transport condi- For transport, bring the electrical connections always into the following con-
tion of the connec- dition.
tions
There is a cable with a plug (3) at the rear of

the 5 m sections.
For transport, the cable is wound around the

holders (1) and the plug is inserted in the
dummy socket (2).
There is a plug socket (1) at the front of each 5

m section.
For transport, the sockets are covered with
protective caps.
20.02.2001

At the 22 m boom Establishing a connection

extension
• Connect the cable of the 10 m section to the socket of the second 5 m sec-
tion at the front.
• Connect the cable of the 5 m section to the socket at the main boom
head, à p. 3 - 58.
Disconnecting
• Detach the electrical connection between 10 m and 5 m section.
• Detach the electrical connection between 5 m section and main boom
head; à p. 3 - 58.
• Prepare the electrical connections at the 5 m section for transport;
à p. 4 - 18.
à p. 3 - 58.
At the 27 m boom Establishing a connection

extension
• Connect the cable of the 10 m section to the socket of the second 5 m sec-
tion at the front.
• Connect the cable of the second 5 m section to the socket of the first
5 m section at the front.
• Connect the cable of the first 5 m section to the socket at the main boom
head; à p. 3 - 58.
Disconnecting
• Detach the electrical connection between the 10 m and front 5 m section.
• Detach the electrical connection between the two 5 m sections.
• Detach the electrical connection between the rear 5 m section and the
main boom head; à p. 3 - 58.
à p. 4 - 18.
à p. 3 - 58.
20.02.2001

4.4.5 Unfolding/folding the deflection sheave on the 5 m section
This section describes only the unfolding and folding of the deflection
sheave on the 5 m section. For folding and unfolding the deflection sheave
on the 10 m section à Folding out / in the deflection sheaves on the 10 m section,
p. 3 - 61.
For work with the boom extension you must fold out the deflection sheaves
on the rear 5 m section.
Fold the deflection sheave for transport.

• Pull the pin (2) out of the bore (3).
• Fold the defection sheave von the strut (1)
upwards until the locking positions are
aligned with the bore hole (3).
• Fasten the deflection sheave with the pin
and secure the pin with a retaining needle.

• Fold the deflection sheave down as far as
possible.
• Insert the pin in the bore hole (3) and secure
it with a retaining needle.
20.02.2001

4.4.6 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 from becoming loose, falling down and injuring
people.
22 m boom extension
27 m boom extension
• Remove the hoist rope holding rollers and rods (1).

• For both boom extensions, guide the hoist rope via the deflection sheaves
(5), (4), (3) and via the head sheave (2) on the 7 m section.
• Put all hoist cable holding rollers and rods back in place and secure them
• Attach the hook tackle. The hoist rope can only be reeved once;
à p. 3 - 65.
20.02.2001

Blank page
20.02.2001

4.5 Driving with rigged crane and rigged boom extension

This section describes how you can move the truck crane with installed
counterweight and rigged boom extension on site (e.g if, because of lack of
space, the boom extension can not be directly installed at the site).
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
Before a rigged crane can be driven, the superstructure must be locked and
the slewing gear permanent brake must be engaged.
4.5.1 Driving route
The route must be a flat, even surface. The level adjustment system cannot
compensate for uneven surfaces. If the surface pressure of the tyres ex-
ceeds the permissible load on the ground, the surface pressure must be in-
creased using packing made of durable material (e.g. wooden planks).
S
levels; à Operating instructions GMK 4075, Part 1 Carrier – Technical data.
20.02.2001

4.5.2 Boom positions and axle loads
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 indica-
11== tor. The SLI code 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
Risk of accidents if SLI is overridden.
Always set the SLI rigging code corresponding to the current rigging mode
when you derrick the main boom into the prescribed position. Do not over-
ride the SLI; the prescribed positions in the following tables are all within
the areas which are permitted according to the Lifting capacity tables.
The truck crane safe load indicator does not function when the SLI is over-
ridden!
20.02.2001

22 m boom The following table only applies if the 22 m boom extension is rigged.
extension Tables for rigged 27 m boom extension; à
p. 4 - 26.
Tables for rigged lattice extension; à
p. 3 - 84.
H
Counter- Telescoping Main Lattice Main Axle load2) Axle load2)

weight Telescope boom exten- boom in t x 1000 lbs
in t section angle sion position1)
I/II/III/IV in ° angle at the rear at the rear
in ° front front
0/0/0/0 15 5 front 14.5 10.0 32.0 22.0

9.13)
0/0/0/0 70 5 rear 11.5 13.0 25.5 29.0
0/0/0/0 15 5 front 14.0 11.0 31.0 24.5
10.1
0/0/0/0 70 5 rear 11.5 13.5 25.5 30.0
0/0/0/0 15 5 front 13.5 12.5 30.0 27.5
12.1
0/0/0/0 70 5 rear 12.5 13.5 27.5 30.0
0/0/0/0 15 5 front 12.0 16.0 26.5 35.5
16.1
0/0/0/0 70 5 rear 14.5 13.5 32.0 30.0
1)Boom position to the rear: 0° position, boom over truck crane rear
edge
line
line
s
20.02.2001

27 m boom The following table only applies if the 27 m boom extension is rigged.
extension Tables for rigged 22 m boom extension; à
p. 4 - 25.
Tables for rigged lattice extension; à
p. 3 - 84.
H
Counter- Telescoping Main Lattice Main Axle load2) Axle load2)

weight Telescope boom exten- boom in t x 1000 lbs
in t section angle sion position1)
I/II/III/IV in ° angle at the rear at the rear
in ° front front
0/0/0/0 15 5 front 16.0 8.5 35.5 19.0

9.13)
0/0/0/0 70 5 rear 10.5 14.0 23.5 31.0
0/0/0/0 15 5 front 15.5 9.5 34.5 21.0
10.1
0/0/0/0 70 5 rear 11.0 14.0 24.5 31.0
0/0/0/0 15 5 front 15.0 11.0 33.0 24.5
12.1
0/0/0/0 70 5 rear 12.0 14.0 26.5 31.0
0/0/0/0 15 5 front 13.5 14.5 30.0 32.0
16.1
0/0/0/0 70 5 rear 14.0 14.0 31.0 31.0
1)Boom position to the rear: 0° position, boom over truck crane rear
edge
line
line
4.5.3 Driving the rigged crane
When driving with a rigged boom extension, proceed in the same way as
for driving with a rigged lattice extension; à
p. 3 - 86.
20.02.2001

4.6.1 Maintenance work M1, monthly
H
For lubricating the pins, use the same grease as stated in the Maintenance
manualfor lubricating attach pins and socket pins; à Maintenance manual
GMK 4075, Maintenance overview – M1 maintenance plan.
• 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.
20.02.2001

Blank page
20.02.2001

5
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

5.2.1 Installing auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
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
5.5 Driving with rigged crane and installed auxiliary single-sheave boom top . . . . 5 - 14
16.02.2001

16.02.2001

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.
If you wish to use the auxiliary single-sheave boom top on several GROVE
truck cranes, it needs to be adapted to the corresponding crane and marked
with all the serial numbers.
S
The tauxiliary single-sheave boom top should only be adjusted by GROVE
Customer Support at the particular location.
The serial number (1) is on a plaste, in the

front on the auxiliary single-sheave boom top.
20.02.2001

5.1 Identification
Blank page
20.02.2001

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 suf-
ficient load bearing capacities; à
Transport dimensions and weights, p. 2 - 1 .
5.2.1 Installing auxiliary single-sheave boom top
On the left side of the main boom head there is a holding device.
When installing, the holding device is connected at the front bore holes (1).
• Loosen the retaining pin and remove the pin

(1) from the bearing point (2).
• Use an auxiliary crane to couple to the con-
nection eyes (3) on the auxiliary single-
sheave boom head and lift it to the left onto
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 auxiliary single-sheave boom
top to the holding device using a pin (1).
• Depending on the application, bring the
auxiliary single-sheave boom top into trans-
port position or working position;
à Rigging the auxiliary single-sheave boom
top, p. 5 - 5.
20.02.2001

5.2.2 Removing the auxiliary single-sheave boom top
• Attach an auxiliary crane to the connection eyes (1) of the boom top.
In the working position, the auxiliary single-sheave boom top is positioned

in front of the main boom head and is fastened with three pins (1).
• Remove the retaining pins and draw all the pins (1) out of the bores and
bearing points.
In the working position, the auxiliary single-sheave boom top is positioned

to the side of the main boom head and is fastened with two pins (1).
• Remove the retaining pins and draw all the pins (1) out of the bores and
bearing points.
• Lift the auxiliary single-sheave boom top

from the head of the main boom.
• Insert the two thin pins (1) and (3) into the
bearing points (2) and (4) on the auxiliary
single-sheave boom top.
• Insert the two pins (5) into the mounting
brackets (6) in front on the auxiliary single-
sheave boom top.
• Secure all the pins using retaining pins.
20.02.2001

5.3 Rigging the auxiliary single-sheave boom top
5.3.1 Rigging in transport position
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.
• Insert both pins into the holders (3) and se-
cure them with retaining pins.
thin pin from the bearing point (4).
• Slew the auxiliary boom top to the side of
the main boom head.
• Using the thin pin (1), fasten the auxiliary sin-

gle-sheave boom top to the bearing point (2).
The auxiliary single-sheave boom top is now

in transport position.
20.02.2001

5.3.2 Rigging in working position
In working position, the auxiliary single-sheave boom top is attached to the
main boom head at both bore holes.

thin pin from the bearing point (1).
• Swing the auxiliary single-sheave boom top
in front of the main boom head.
• 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.
• Insert the thin pin (4) into the bearing point
and secure it with a retaining pin.
The auxiliary single-sheave boom top is now

in working position.
20.02.2001

5.3.3 Attaching and removing hoist cable
• Remove the cable holding rods (1) from the

head of the main boom and from the auxil-
iary single-sheave boom top.
• When reeving, guide the hoist cable over the
left head sheave of the main boom.
• Insert the rope 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.
Reverse the sequence of operations to remove the hoist cable before slew-
ing the auxiliary boom top into transport position.
5.3.4 Possible reeving methods on the auxiliary single-sheave boom top
The hoist cable may only be simply reeved (single drop).
Hook tackle, max. lifting capacity: 8 t

for single-reeving 5 t (11,000 lbs)
1-sheave hook block, max. load bearing capacity 20 t

for simple reeving 5 t (11,000 lbs)
for two falls reeving 10 t (22,000 lbs)
20.02.2001

5.3.5 Lifting limit switch and anemometer
In operation
• Pull the plug of the connecting cable from

• Unwind the connecting cable from the hold-
ers (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; à
Operating instructions
GMK 4075, Part 2 Superstructure – Rigging work.
During transport
• Insert the plug of the connecting cable into

• Wind the connecting cable onto the
holders (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; à Operating instructions GMK 4075, Part 2 Su-
perstructure – Rigging work.
20.02.2001

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
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 individ-
ual parts of the truck crane being overloaded. The SLI then no longer pro-
vides protection.
Two-hook operation with the boom extension (additional equipment) is not
permitted!
G
The load must always be lifted with the weakest part first (auxiliary single-
sheave boom top).
H
For information on the position and function of the operating instruments
required; àOperating instructions GMK 4075, Part 2 Description of the truck
crane (crane section).
Prerequisites 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
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.
20.02.2001
s
Setting SLI For two-hook operation, both hoists must be activated on the SLI.
H
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 elimi-
nates the need for input later during operation. Proceed as follows:

32 When the main hoists are switched off, the main hoist on/off indicator lamp in
the Main menu on the Crane control and auxiliary hoist on/off display lights up
red.
• Switch on the main hoist.

ä Additionally, press the main hoist on/off rocker switch down once. The indi-
cator lamp in the rocker switch lights up brightly.
Lamp I for the main hoist lights up in the hoists indicator lamps.
• In the display reeving, enter the quantity of reeved cable of the main hoist
§ cable on the main boom.
Now the reeving for the main hoist is stored and you can switch to the aux-
iliary hoist.

32 For this, press down once both the rocker switches main hoist on/off and
• Switch on the auxiliary hoist.

å Additionally, press the auxiliary hoist on/off rocker switch down once. The
indicator lamp in the rocker switch lights up brightly.
20.02.2001

On the indicator lamps hoists, lamp II is flashing for the auxiliary hoist.
• In the display reeving, enter the number of reeved ropes on the auxiliary
4 hoist rope of the auxiliary single-sheave boom top.
Now the reeving for the auxiliary hoist is also stored and you can switch on
the main hoist.
ä Switch on the main hoist.

Additionally, press the main hoist on/off rocker switch down once. The indica-
tor lamp in the rocker switch lights up brightly.
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 top,
11== valid for the current rigging mode of the truck crane.
Now the SLI is set for two-hook operation, taking into account the reeving
for the auxiliary hoist and the lifting capacity table for the main boom.
H
The load measurement is taken with the pressure in the derricking cylinder.
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 auxiliary single-
sheave boom top.
20.02.2001
s
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.
Therefore move the load at the lowest possible speed!
H
As soon as the hoist rope on the main boom is pulled taut, the status display
actual load will exhibit slight deviations. However, the differences are on the
safe side with regard to SLI shutdown.
H
With two-hook operation, the SLI code for the main boom remains activated
during the entire hoist procedure.
• Lift the load completely off the ground with the auxiliary single-sheave
boom top.
• Only now should you attach the load to the hook block of the main boom
as well.
• Now lift the load with the hook block on the main boom until both slinging
points are at the same height.
20.02.2001

• Reel off hoist rope on the auxiliary single-sheave boom top until the load
is hanging from the hook block on the main boom only.
Turning the load is thus completed.
20.02.2001

5.5 Driving with rigged crane and installed auxiliary single-sheave boom top
5.5 Driving with rigged crane and installed auxiliary single-

sheave boom top
G
Accidents may occur when driving from the crane cab.
Before driving with rigged lattice extension observe all the instructions in
the section Driving the truck crane from the crane cabin and set the rigging code
described therein for free-standing works.
When driving with rigged lattice extension proceed exactly as prescribed in

the section Driving the truck crane from the crane cabin; à
Operating instruc-
tions GMK 4075 – Part 2 Superstructure.
20.02.2001

6
6 Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
16.02.2001

16.02.2001

Index
6 Index
H
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 the respective
chapters Description of the truck crane in the Operating instructions GMK 4075.
From there, you will be referred to more detailed descriptions of these elements.
16.02.2001

Index
Blank page
16.02.2001

Index
A Auxiliary single-sheave boom top

driving with installed auxiliary single-sheave boom top . . . . . . . . . . . . . . . . 5 - 14
mounting / removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
possible reeving methods; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
rigging
in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
in working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Axle loads
for driving with rigged boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
when driving with rigged lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 84
B Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2

organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
safety instructions for truck crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
assembly of boom extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
boom extension slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
CHECK LIST
rigging the 22 m/27 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
unrigging the 22 m/27 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Driving with an installed boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
Driving with rigged boom extension
axle loads and boom positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
Rigging work
establishing/disconnecting electrical connection . . . . . . . . . . . . . . . . . . . 4 - 18
establishing/disconnecting the hydraulic connection . . . . . . . . . . . . . . . . 4 - 15
installing/removing 5 m sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
positioning/removing the hoist cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21
unfolding/folding the deflection sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
E Electrical system
at the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 58
H Hoist rope
possible reeving methods on the auxiliary single-sheave boom top . . . . . . . 5 - 7
possible reeving methods on the boom extension . . . . . . . . . . . . . . . . . . . . . 3 - 65
16.02.2001
possible reeving methods on the lattice extension . . . . . . . . . . . . . . . . . . . . . 3 - 65

Hydraulic system

Index
I Identification
of the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
of the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
of the two-stage swing-away lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Important information about these operating instructions . . . . . . . . . . . . . . . . . . 1-1
L Lattice extension
assembly of the lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
centres of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
CHECK LIST
installing the two-stage swing-away lattice extension . . . . . . . . . . . . . . . 3 - 10
removing two-stage swing-away lattice extension . . . . . . . . . . . . . . . . . . 3 - 12
rigging the 10 m swing-away lattice extension . . . . . . . . . . . . . . . . . . . . . 3 - 14
rigging the 17 m two-stage swing-away lattice extension . . . . . . . . . . . . 3 - 23
unrigging the 10 m swing-away lattice extension . . . . . . . . . . . . . . . . . . . 3 - 18
unrigging the 17 m two-stage swing-away lattice extension . . . . . . . . . . 3 - 27
driving with rigged lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 83
axle loads and boom positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 84
maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 93
rigging work
checking the transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35
connections on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 53
connections on the main boom head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 49
connections with folded lattice extension
in front area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 43
in middle area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 45
in rear area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 47
establishing/disconnecting electrical connection . . . . . . . . . . . . . . . . . . . 3 - 58
establishing/disconnecting the hydraulic connection . . . . . . . . . . . . . . . . 3 - 60
folding deflection sheave out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 61
folding the run-up rail out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 41
hose drum hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 38
installing the two-stage swing-away lattice extension . . . . . . . . . . . . . . . 4 - 14
positioning/removing the hoist cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 64
swinging the 7 m section in front of the 10 m section . . . . . . . . . . . . . . . 3 - 57
swinging the lattice extension onto the main boom . . . . . . . . . . . . . . . . . 3 - 55
turning the lattice extension in front of the main boom . . . . . . . . . . . . . . 3 - 56
M Maintenance work
on the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
Malfunctions
when working with lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 91
when working with the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 91
16.02.2001
Measurement in US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10

Index
S SLI
shutdown during. during work with the boom extension . . . . . . . . . . . . . . . 3 - 75
switching off when working with the lattice extension . . . . . . . . . . . . . . . . . 3 - 75
T Transport condition
of the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35
in metric units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
in US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
Turning loads
with the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77
16.02.2001

Operating Instructions Lattice Extension: 2 084 629 en 2 084 629 en

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2 084 629 en Operating instructions lattice extension GMK 4075

2 Transport dimensions and weights

3 Two-stage swing-away lattice extension (additional equipment)

4 Boom extension (additional equipment)

5 Auxiliary single-sheave boom top (additional equipment)

Operating instructions lattice extension GMK 4075 2 084 629 en

2 084 629 en Wartungsanleitung GMK 4075

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

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

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

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

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

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

Operating instructions lattice extension GMK 4075 2 084 629 en

2 084 629 en Operating instructions lattice extension GMK 4075

1.1 About these operating instructions

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

Operating instructions lattice extension GMK 4075 2 084 629 en 1-1

1.2 Basic safety instructions

1.2.1 Warnings and symbols

1-2 2 084 629 en Operating instructions lattice extension GMK 4075

1.3 Proper use

Proper use also entails

– observing all crane documentation consisting of the operating instruc-

Improper use includes

– transporting loads on the carrier

1-4 2 084 629 en Operating instructions lattice extension GMK 4075

1.4 Organizational measures

This could include:

Operating instructions lattice extension GMK 4075 2 084 629 en 1-5

Do not make any changes to the programmable controlsystems (e.g. the

– the installation of safety devices,

Replacement parts must fulfill the technical requirements prescribed by the

It is imperative that appropriate service equipment be used when carrying

1-6 2 084 629 en Operating instructions lattice extension GMK 4075

1.5 Personnel qualifications

Only reliable personnel may operate the truck crane.

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

Only experienced personnel familiar with the applicable accident preven-

Your responsibilities as a crane operator (including those concerning traffic

Only trained, experienced personnel with special knowledge in the fields of

Operating instructions lattice extension GMK 4075 2 084 629 en 1-7

1.6 Safety instructions for truck crane work

1-8 2 084 629 en Operating instructions lattice extension GMK 4075

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

Simultaneously lifting loads with two cranes is particularly dangerous. Use

Operating instructions lattice extension GMK 4075 2 084 629 en 1-9

1.7 Specifications in US units of measurement

– The first column shows the metric units of measurement.

Prescribed length in Corresponding length in Rounded length in

1 - 10 2 084 629 en Operating instructions lattice extension GMK 4075

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

Operating instructions lattice extension GMK 4075 2 084 629 en

2 084 629 en Operating instructions lattice extension GMK 4075

2 Transport dimensions and weights

2.1 In metric units

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

Description Length x width x Weight (kg)