Grove Crane GMK6300 Operating Instructions for Megalift 2084993 - PDF DOWNLOAD

Serial number:

2 084 993 en 09.08.2005

Important note

Duplications of any kind and excerpts from this document are not subject to the revision service.

Original documents of Deutsche GROVE GmbH are marked with the blue serial number of the truck crane on the cover sheet.

Duplications and print-outs of data carriers on which Deutsche GROVE GmbH has delivered this document are also not subject to the revision service.

Copyright reserved by Deutsche GROVE GmbH

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

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©

The following chapters are contained in these operating instructions:

1 Important information 2 Transport dimensions and weights 3 Megalift 4 Operation with main boom and Megalift 5 Operation with heavy load lattice extension and Megalift

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6 Alphabetical index

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INHALTSVERZEICHNIS

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Operating manual for Megalift GMK 6300

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1

1

Important information

1.1

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

1.2

Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

1.2.1

Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1- 3

1.3

Proper use

1.4

Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7

1.5

Qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9

1.6

Safety instructions for work with the truck crane . . . . . . . . . . . 1 - 11

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Operating manual for Megalift GMK 6300

Important information 1.1 About these operating instructions

1 1.1

Important information

H

Validity of these operating instructions

About these operating instructions The Megalift described in these operating instructions can be obtained as additional equipment.

These operating instructions only apply to original parts supplied by Deutsche GROVE GmbH and describe the operation of the Megalift.

In addition, all the data given in the Operationg instructions supplied for the GMK 6300, for which the Megalift is supplied, also apply for the operation of the truck crane.

For the operation of the truck crane with the lattice extension described in these operating instructions, but without the Megalift, the GMK 6300 Lattice extension operating instructions apply.

Prerequisites for assembly and operation

The Megalift described in these operating instructions may only be operated together with a GROVE GMK 6300 truck crane whose serial number is identical with the serial number that is marked on the Megalift.

Safety instructions

The operation of the GMK 6300 with the Megalift described in these operating instructions is subject to – the basic safety instructions to be found in the subsequent section Basic safety instructions and – the safety instructions contained in the supplied operating instructions for the GMK 6300.

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Reference to other operating instructions

Cross references to other operating or maintenance instructions are shown in the following forms: ➠ GMK 6300 Operating instructions, Part 1 Superstructure – Rigging work You will find the number of the chapter bearing the name Rigging work at the front, on the second page of the stated operating instructions. or ➠ GMK 6300 Operating instructions – Safe load indicator The corresponding page number can be found in the index.

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Important information 1.1 About these operating instructions

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Important information 1.2 Basic safety instructions

1.2

Basic safety instructions

1.2.1

Warnings and symbols The following definitions and symbols are used in the operating instructions to highlight particularly important information:

G S B O 09.08.2005

H

s

This symbol indicates hazards related to the operation described that may cause personal injury. The type of danger (e.g. danger of fatal injury, personal injury or risk of crushing) is normally specified in the warning sign.

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

This symbol alerts you to situations where there is a danger of receiving an electric shock.

This symbol reminds you that you are working with substances which pose a risk to the environment. Take particular care. Further information on handling substances that pose a risk to the environment; ➠ Maintenance manualnce instructions, 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.

The hand with the pointing finger indicates passages that contain additional instructions and tips with regard to truck crane operation.

This symbol indicates that the topic is continued on the next page. Turn to the next page!

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Important information 1.2 Basic safety instructions

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Important information 1.3 Proper use

1.3

Proper use The truck crane GMK 6300 was constructed in accordance with state of the art technology and the recognized safety regulations. Nevertheless, personal injury to the operator or a third party as well as damage to the crane and other property may occur during use.

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

The GMK 6300 truck crane must be in proper working condition and may only be used 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 corrected immediately.

The GMK 6300 truck crane may only be operated at temperatures of between –25 and +40 °C if it is not equipped with the relevant special equipment.

The GMK 6300 truck crane is to be used exclusivly for vertical lifting of loads whose weight and centre of distribution are known. A hook block must be reeved on the hoist rope and such lifting must be done 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 improper or unauthorized use of the GMK 6300 truck crane. The user shall take on full responsibility for any such use.

Proper use also entails – observing all crane documentation consisting of the operating instructions, the lifting capacity table, the outrigger pressure table and the safety manual

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– following the inspection and maintenance requirements specified in the maintenance manual.

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Important information 1.3 Proper use

Improper use includes: – transporting loads on the carrier – pushing, pulling or lifting loads with the level adjustment system, the beams or the outrigger cylinders – pushing, pulling or lifting loads off the ground using the slewing gear, the derricking gear or the telescoping gear – pulling off fixed objects using the crane – two-hook operation with the boom extension and two-hook operation on the main boom head without additional equipment – operation when crane is not on outriggers (free on wheels) – defining SLI codes that do not correspond to the actual rigging mode – working with an overridden SLI or overridden lifting limit switch – after SLI deactivation, 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 people in any way with the lifting tackle, upon the load, or in the crane cab while driving – carrying passengers outside the driver’s cab – loading and unloading work, i.e. continuous operation without a sufficiently long break – usage for any kind of sport or recreation event, especially for bungee jumping – operation of the truck crane with Megalift and luffing jib or Megalift and heavy load lattice extension or Megalift and boom extension

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– operation of the mobile crane with erected and non-braced Megalift.

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Important information 1.4 Organisational measures

1.4

Organisational 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 capacity table, observe 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 information required to carry out the work before starting operations. Give your employees (e.g. banksmen, slingers, rigging personnel) appropriate instructions.

Ensure that the maintenance personnel possess the necessary know-how to safely operate the crane. Ensure that the maintenance personnel have access 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.

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Observe all safety and warning signs on the truck crane.

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

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Important information 1.4 Organisational measures

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

Familiarize yourself with the location and operation of the fire 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 operating safety, stop the machine immediately and inform the appropriate responsible persons.

Do not make any changes to the programmable control systems (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 Product Support before doing any welding work.

Ensure that both the prescribed periods and the periods specified in the operating 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.

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It is imperative that appropriate service equipment be used when carrying out repair work.

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Important information 1.5 Qualification of personnel

1.5

Qualification of personnel 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 supervision.

Only reliable personnel may operate the truck crane.

As a truck crane operator you are obliged to fulfill a number of requirements: – 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 qualifications that may be required by the country in which you are working.

– You must be familiar with and have understood the operating instructions.

– You must be familiar with and have understood the accident prevention regulations.

– You must fulfil all physical and mental requirements for truck crane operation, 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 prevention 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 maintenance work on the truck crane.

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Deutsche GROVE GmbH gives general and type-related crane operator and technical courses.

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Important information 1.5 Qualification of personnel

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Important information 1.6 Safety instructions for work with the truck crane

1.6

Safety instructions for work with the truck crane 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 condition of the truck crane carefully using the check lists in the operating instructions. 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 maintenance work on machine sections above body height which have no apparatus 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 using cordons and mark them as such.

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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 diagonally (e.g. from a vehicle or scaffolding) Inform banksmen and helpers about this as well.

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Important information 1.6 Safety instructions for work with the truck crane

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 belongs 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.

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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 operating conditions in the Safety manual, and observe the relevant national regulations.

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2

2

Transport dimensions and weights

2.1

Transport dimensions and weights in metric units . . . . . . . . . . . 2 - 1

2.1.1

2.2

2- 1

Transport dimensions and weights in US units . . . . . . . . . . . . . 2 - 1 Megalift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.2.1

Megalift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transport dimensions and weights 2.1 Transport dimensions and weights in metric units

2

Transport dimensions and weights

2.1

Transport dimensions and weights in metric units This section contains the transport dimensions and weights of the Megalift in metric units.

2.1.1

2.2

Megalift Description

Length x Width x Height (m)

Weight (kg)

Megalift, complete

12.00 x 2.75 x 2.40

5 500

Transport dimensions and weights in US units This section contains the transport dimensions and weights of the Megalift in US units.

Megalift Description

Length x Width x Height (ft)

Weight (lbs)

Megalift, complete

39.4 x 9.0 x 7.9

12 130

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2.2.1

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Transport dimensions and weights 2.2 Transport dimensions and weights in US units

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3

Megalift

3.1

Supplementary instructions to the GMK 6300 operating instructions when Megalift is installed . . . . . . . . . . . . . . . . . . . 3 - 1

3.1.1 3.1.2 3.1.3

Rope grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe load indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3- 1 3- 2 3- 3

3.2

Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4

3.3

Additional operating and display elements in the crane cab . . . . . 3 - 7

3.3.1 3.3.2

Location of the additional operating and display elements . . . . . . . . . .

Function of the additional operating and display elements . . . . . . . . . .

3- 8 3 - 10

3.4

Components and identification . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

3.5

Slinging points and lashing eyes . . . . . . . . . . . . . . . . . . . . . . 3 - 15

3.6

Checklists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17

3.6.1 3.6.2

3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.7.6 3.7.7 3.7.8 3.7.9 3.7.10 3.7.11 3.7.12 3.7.13 3.7.14

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3

3.7.15 3.7.16 3.7.17 3.7.18 3.7.19 3.7.20 3.7.21 3.7.22

CHECKLIST: Installing the Megalift . . . . . . . . . . . . . . . . . . . . . . .

CHECKLIST: Removing the Megalift . . . . . . . . . . . . . . . . . . . . . . .

3 - 18 3 - 23

Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27 Removing/installing the support for telescopic swing-away lattice extension Slinging the Megalift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pushing in/pulling out the supports . . . . . . . . . . . . . . . . . . . . . . .

Guide rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pulling out/pushing in the plastic supports . . . . . . . . . . . . . . . . . . .

Establishing/releasing a lock between the rope winch and the main boom .

Establishing/releasing a lock between the Megalift and the main boom . . .

Lowering the Megalift onto the main boom . . . . . . . . . . . . . . . . . . .

Establishing/releasing a connection between the rope winch and the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Establishing/releasing a lock between the gantry mast and the rope winch .

Releasing/locking the bridle . . . . . . . . . . . . . . . . . . . . . . . . . . .

Releasing/securing the bridle pendant links . . . . . . . . . . . . . . . . . . .

Establishing/releasing a lock between the rear pendant links and the gantry mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Establishing/releasing the lock between the rear pendant links and the main boom basic section . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working position/transport position of the raising cylinder . . . . . . . . . .

Establishing/breaking the electrical connection . . . . . . . . . . . . . . . . .

Working position/transport position of the angle sensor . . . . . . . . . . .

Establishing/breaking the hydraulic connection . . . . . . . . . . . . . . . . .

Reeving the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising and setting down the gantry mast . . . . . . . . . . . . . . . . . . .

Lock/release lock of bridle pendant links to telescopic section III . . . . . . .

Pre-tensioning the Megalift . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 - 27 3 - 30 3 - 31 3 - 32 3 - 33 3 - 35 3 - 36 3 - 37 3 - 39 3 - 40 3 - 42 3 - 43 3 - 44 3 - 46 3 - 47 3 - 48 3 - 51 3 - 52 3 - 54 3 - 55 3 - 57 3 - 58

3.8 3.8.1 3.8.2 3.8.3 3.8.4

Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 59 Maintenance plan D: daily . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance plan W: weekly . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 3 maintenance plan: every 3 months/after 300 op. hours . . . . . . . . . .

M 12 maintenance plan: every 12 months/after 1000 op. hours . . . . . . . .

3 - 59 3 - 59 3 - 60 3 - 60

3.9

Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 61

3.10

Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 63 Checking the position of the rope on the winch drum . . . . . . . . . . . . .

Checking the winch gearbox for tightness . . . . . . . . . . . . . . . . . . . .

Checking the oil level of the winch gearbox . . . . . . . . . . . . . . . . . . .

Checking the condition of the guy rope . . . . . . . . . . . . . . . . . . . . .

Lubricating the winch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil change on the winch gearbox . . . . . . . . . . . . . . . . . . . . . . . .

3 - 63 3 - 64 3 - 64 3 - 65 3 - 69 3 - 70

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3.10.1 3.10.2 3.10.3 3.10.4 3.10.5 3.10.6

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Megalift 3.1 Supplementary instructions to the GMK 6300 operating instructions when Megalift is installed

3 3.1

Megalift Supplementary instructions to the GMK 6300 operating instructions when Megalift is installed When Megalift is installed, the following changes to the operation of your truck crane must be observed: – the transport mounting for the rope grab is relocated – the function of the membrane switch on the SLI changes and – the menu of the crane control is supplemented by the menu Megalift operating values.

Observe the information in the following sections concerning this.

3.1.1

Rope grab Since the hoist ropes are always guided between the Megalift and the main boom when the Megalift is installed, the rope grab is not necessary for operation with the operation.

This means that any rope grab which is installed must be removed before installation of the Megalift.

The transport mounting (1) for the rope grab (2) is on the left-hand side of the main boom.

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If you remove the Megalift and wish to operate the crane without it, the rope grab must be reinstalled.➠ GMK 6300 Operating instructions

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3-1

Megalift 3.1 Supplementary instructions to the GMK 6300 operating instructions when Megalift is installed

3.1.2

Safe load indicator If an SLI code for operation with Megalift has been entered, the tensioning angle is displayed in the information display (1) when the membrane button (2) is pressed.

The tensioning angle is the angle to which the main boom has to be derricked for the tensioning of the Megalift to be enabled.

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The tensioning angle is only indicated when the main boom is at a telescope status for which capacity diagrams are available with Megalift. In all other cases the display shows ====.

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Megalift 3.1 Supplementary instructions to the GMK 6300 operating instructions when Megalift is installed

3.1.3

Crane control

ü

When the Megalift is rigged and the Megalift control system is switched on, the following Megalift operating values can be called up by pressing Membrane switch F3: – Extended length of the tension cylinder in the rope winch in percent – The angle between the gantry mast and the main boom in degrees – Pre-tensioning force of the tension cylinder in kN (actual value) – Pre-tensioning force of the tension cylinder in kN (set value)

üü

• Press the membrane switch twice. When pushed once the switch selects the Control lever emergency program menu. When pushed twice the Megalift operating values menu appears.

MEGALIFT STATUS 50

α [°] :

F [kN] :

30

(40)

24.0

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l [%] :

The menu shows the extended length of the tension cylinder as a percentage; next to this, the current angle between the gantry mast and the main boom is displayed.

In the lower line, the actual and set values of the pre-tensioning force of the tension cylinder are displayed.

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Megalift 3.2 Mode of operation

Mode of operation

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3.2

3-4

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Operating manual for Megalift GMK 6300

Megalift 3.2 Mode of operation

The Megalift is a steel construction consisting of a gantry mast (7), a rope winch (5) and the rear pendant links (6). The gantry mast is locked to the basic section of the main boom. On the gantry mast there are two hydraulic cylinders (8) to raise the steel construction (raising cylinder). There is a further hydraulic cylinder (4) in the winch, for tensioning the rope winch.

For operation, the rope winch is separated from the gantry mast and bolted to the main boom.

Using the two raising cylinders (8), the gantry mast is first raised partially for rigging and then, for working, it is raised to the 90° position. The rear pendant links locked to the main boom stabilise the raised gantry mast in its position.

The rope winch is used to tension the construction. To do this, the rope (1) runs over the gantry mast, is diverted over the bridle (2) and is fastened at the head of the gantry mast. To tension, the bridle is fastened to end of telescopic section III using the bridle pendant links (3).

After the telescopic section has been telescoped and locked, the tensioning procedure is carried out in two stages. First pre-tensioning is carried out with the hydraulic motor pulling the rope tight with a force of ca.

1 t. For the actual tensioning procedure, the hydraulic cylinder in the rope winch rotates it until it is in a position where it can be locked. This procedure is carried out automatically.

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The stress thus created in the boom system compensates for the force which arises when a load is lifted by the boom. In this way, the whole boom is balanced and the load bearing capacity increased.

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Megalift 3.2 Mode of operation

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Megalift 3.3 Additional operating and display elements in the crane cab

3.3

Additional operating and display elements in the crane cab

09.08.2005

This section describes operating and display elements which are additionally installed in the crane cab for the operation of the Megalift.

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Megalift 3.3 Additional operating and display elements in the crane cab

Location of the additional operating and display elements

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3.3.1

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Megalift 3.3 Additional operating and display elements in the crane cab

➠ p. 3-10

2 Rocker switch for raising/lowering gantry mast

➠ p. 3-10

3 Megalift control system rocker switch with lock button

➠ p. 3-10

4 “Winch locked” indicator lamp

➠ p. 3-10

5 “Winch unlocked” indicator lamp

➠ p. 3-11

6 Rocker switch for locking/unlocking winch

➠ p. 3-11

7 Rocker switch for winding/unwinding winch

➠ p. 3-11

8 “Tension cylinder position” indicator lamp

➠ p. 3-11

9 “Megalift tensioned” indicator lamp

➠ p. 3-12

10 “Automatic tensioning” rocker switch

➠ p. 3-12

11 “Tensioning enabled” indicator lamp

➠ p. 3-12

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1 “Gantry mast in 90° position” indicator lamp

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Megalift 3.3 Additional operating and display elements in the crane cab

3.3.2

Function of the additional operating and display elements

Y

S

.

Indicates which position the Megalift is in.

Indicator lamp lit:

Gantry mast is in 90° position

Indicator lamp goes out:

Gantry mast is not in 90° position

Indicator lamp flashes:

At least one of the two proximity switches is registering an incorrect final position for the gantry mast

Rocker switch for raising/lowering gantry mast By pressing the button, the gantry mast is raised or lowered. The rocker switch is only active when the winch is unlocked.

Press rocker switch up:

Gantry mast is raised

Press rocker switch up:

Gantry mast is lowered

Megalift control system rocker switch with lock button Switches the entire control system of the Megalift unit on or off.

Press rocker switch up:

Megalift control system is switched off

Press rocker switch down:

Megalift control system is switched on

“Winch locked” indicator lamp Indicates whether the rope winch is locked.

Indicator lamp lit:

Locked end state

Indicator lamp goes out:

Unlocked end state

Indicator lamp flashes:

No end state reached

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â

“Gantry mast in 90° position” indicator lamp

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Megalift 3.3 Additional operating and display elements in the crane cab

à

V

T

Indicates whether the rope winch is unlocked.

Indicator lamp lit:

Unlocked end state

Indicator lamp goes out:

Locked end state

Indicator lamp flashes:

No end state reached

Rocker switch for locking/unlocking winch By pressing the button, the rope winch is locked, unlocked or slackened.

Press rocker switch up:

Rope winch is locked

Press rocker switch up:

Rope winch is unlocked/slackened

Rocker switch for winding/unwinding winch By pressing the button, the rope winch is reeled onto or off the drum.

Press rocker switch up:

Rope winch is reeled off the drum

Press rocker switch down:

Rope winch is reeled onto the drum

“Tension cylinder position” indicator lamp Indicates that the tension cylinder is completely retracted.

Indicator lamp lit:

Tension cylinder is completely retracted

Indicator lamp goes out:

Tension cylinder is not completely retracted

Indicator lamp flashes:

Tension cylinder cannot be retracted (load on the pin is too large)

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U

“Winch unlocked” indicator lamp

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Megalift 3.3 Additional operating and display elements in the crane cab

W

X

“Megalift tensioned” indicator lamp Indicates that the raised Megalift is tensioned.

Indicator lamp lit:

Megalift is raised and tensioned

Indicator lamp goes out:

Megalift is not tensioned

Indicator lamp flashes:

The tension cylinder is completely extended

“Automatic tensioning” rocker switch By pressing the button the complete tensioning procedure is carried out automatically. The prerequisite for this is that the Tensioning released indicator lamp lights up.

Press rocker switch up:

X

@

Tensioning procedure will start and be completed automatically for as long as the button is held down

“Tensioning released” indicator lamp Indicates whether all the conditions for automatic tensioning have been fulfilled and that automatic tensioning is subsequently enabled.

Indicator lamp lit:

Automatic tensioning procedure is enabled (all conditions fulfilled)

Indicator lamp goes out:

The function of the button is blocked (at least one of the conditions has not been fulfilled)

Membrane switch “Power unit speeds/Critical load control” (Button in the crane control)

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Pressing the switch selects the Driving gear speed/Critical load control menu.

This menu is used to enter the respective maximum driving gear speed for slewing gear, hoist gear, telescoping gear, derricking gear and rope winch of the Megalift; ➠ Driving gear speeds/Critical load control menu in the GMK 6300 Operating manual.

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Megalift 3.4 Components and identification

3.4

Components and identification

Components

The scope of delivery includes the following components: – the gantry mast – the rope winch – the rear pendant links – the slinging tackle

Identification

S H

Only operate the truck crane with those parts of the Megalift which have the same serial number as the crane.

The SLI is only set for this Megalift.

This prevents malfunctions and damage.

For technical reasons a truck crane may only be set with one Megalift.

If you wish to use the Megalift on several GROVE truck cranes, the parts of the Megalift must be adjusted for these cranes and labelled with all of the respective serial numbers.

The matching of the Megalift may only be carried out by CraneCARE.

09.08.2005

S

The Megalift is designed for the truck crane for which it was delivered.

Parts of the Megalift belonging to the truck crane have the same serial number as the truck crane. All components are identified by serial numbers.

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Megalift 3.4 Components and identification

Serial numbers on the gantry mast The gantry mast is marked with the serial number (1).

Serial number on the rope winch

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The rope winch is marked with the serial number (1).

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Megalift 3.5 Slinging points and lashing eyes

3.5

Slinging points and lashing eyes

Slinging points

G

The following illustration shows the slinging points on the Megalift.

Only sling the Megalift at these slinging points and with the lifting gear supplied, so that it automatically has the correct centre of gravity.

The number of slinging points and supplied slinging tackle varies according to the Megalift version. Slinging points and ropes that belong together are marked with letters.

Version with four slinging points There are four slinging points (2) and (3) on the Megalift.

The corresponding slinging tackle (1) with four ropes is supplied.

3

Version with three slinging points There are three slinging points (3) on the Megalift.

The corresponding slinging tackle (1) with three ropes is supplied.

09.08.2005

H

Depending on whether you are using a single hook or a double hook, the slinging tackle needs to be attached to the hook in different ways; ➠ p. 3-30.

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Megalift 3.5 Slinging points and lashing eyes

Lashing eyes

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There are four lashing eyelets (2) on the Megalift (1), with which it can be lashed securely to the separate vehicle.

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Megalift 3.6 Checklists for rigging work

3.6

Checklists for rigging work This section contains the CHECKLIST: Installing the Megalift; ➠ p. 3-18, the CHECKLIST: Removing the Megalift; ➠ p. 3-23 and a description of how to carry these out; ➠ p. 3-27.

The following conditions must be fulfilled for installation/removal of the Megalift: – The truck crane must be properly supported on outriggers and aligned horizontally.

– The main boom must be completely retracted.

For installing and removing the Megalift, no counterweight should be fitted.

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H

– An auxiliary crane and a working platform must be available.

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Megalift 3.6 Checklists for rigging work

3.6.1

H

CHECKLIST: Installing the Megalift This checklist is not equivalent to complete operating instructions. There are accompanying instructions, which are indicated by cross-references.

Observe the warning and safety instructions given there.

Prerequisites: – With additional equipment, the telescopic swing-away lattice extension and the pertaining support are removed; ➠ p. 3-27.

– The Megalift is standing on the extended supports.

– The crane cab is not inclined.

– The main boom is lowered to about 2°.

1. Tie down the Megalift unit at the slinging points with an auxiliary crane and the rope tackle supplied (note the designation of the ropes!!) and hoist the Megalift; ➠ Tying down the Megalift, p. 3-30.

2. Push in the supports, and secure; ➠ Pushing in the supports, p. 3-31.

3. Attach guide rope to the Megalift unit; ➠ Guide rope, p. 3-32.

4. Check whether the plastic supports are pushed in; if necessary, push in and secure; ➠ Pushing in plastic supports, p. 3-33.

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5. Remove the securing pins from the retainers for the rope winch plugs on the main boom; ➠ Fastening/loosening locking pins between the rope winch and the main boom, p. 3-35.

F0067

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Megalift 3.6 Checklists for rigging work

6. Lift the Megalift unit over the main boom and lock it to the main boom basic section at the front; ➠ Locking the Megalift unit, p. 3-36.

7. Pull out the fastening pins for the rear pendant links at the foot of the main boom; ➠ Before lowering, p. 3-37.

F0069

8. Turn the angle sensor round and lock it; ➠ Bringing the angle sensor into the working position, p. 3-51.

H F0068

Make sure that the winch plugs thread through the retainers and that the rear pendant links at the foot of the main boom basic section thread through the locking points.

9. Slowly lower the Megalift unit with the auxiliary crane as far as the main boom basic section; ➠ Lowering, p. 3-38.

F0070

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10. Bring the raising cylinder of the Megalift unit into position and lock to the main boom basic section, then secure the turnbuckle at the gantry mast again; ➠ Bringing the raising cylinder into the working position, p. 3-47.

11. Establish a hydraulic connection for the Megalift at the front by the main boom; ➠ Hydraulic connection – Establishing – At the raising cylinder, p. 3-52.

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Megalift 3.6 Checklists for rigging work

12. Secure the rope winch plugs in the retainers on the main boom using the securing pins; ➠ Establishing/releasing a lock between the rope winch and the main boom, p. 3-35.

F0072

13. Connect the rope winch and the main boom basic section with the folding catch; ➠ Establishing a connection between the rope winch and the main boom, p. 3-39.

14. Establish a hydraulic connection at the rope winch; ➠ Hydraulic connection – Establishing – At the rope winch, p. 3-52.

15. With the ignition turned off, establish electrical connection at the rope winch; ➠ Electrical connection – Establishing – At the rope winch, p. 3-48.

16. Remove bolt between gantry mast and rope winch; ➠ Reomove locking pin between gantry mast and rope winch, p. 3-40.

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17. Remove locking pin between bridle and gantry mast; ➠ Remove bridle, p. 3-42.

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Megalift 3.6 Checklists for rigging work

18. Release the retaining pins at the bridle straps, and at the joint locks at the bridle straps; ➠ Releasing/securing the bridle pendant links and the joint locks, p. 3-43.

19. Release the connection between the rear pendant links and the gantry mast; ➠ Releasing the rear pendant links, p. 3-44.

F0074

20. Lock the rear pendant links to the main boom basic section; ➠ Locking the rear pendant links to the main boom basic section, p. 3-46.

S

21. Raise gantry mast to 5° with the raising cylinders; ➠ Raising the gantry mast, p. 3-55.

22. Pull out the plastic supports, and secure; ➠ Pulling out the plastic supports, p. 3-33.

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23. Move the gantry mast into the final position (90°) with the raising cylinders; ➠ Raising the gantry mast, p. 3-55.

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Megalift 3.6 Checklists for rigging work

V

24. Unlock the rope winch; ➠ Raising the gantry mast, p. 3-55.

25. Slowly unwind the rope winch and lock the bridle strap at the collar of telescopic section III; ➠ Locking the bridle pendant links to telescopic section III /removing the lock; p. 3-57.

T

26. Wind up rope winch and use engine power to pull tight, lock winch; ➠ Pre-tensioning the Megalift, p. 3-58.

27. Place hoist rope in position and secure at main boom head; ➠ Rope guide on the main boom, p. 3-54.

28. Reeve the hoist rope at the hook block and attach the lifting limit switch weight to it; ➠ Reeving the hoist rope, p. 3-54.

09.08.2005

29. To work with Megalift; ➠ p. 4-1.

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Megalift 3.6 Checklists for rigging work

3.6.2

H

CHECKLIST: Removing the Megalift This checklist is not equivalent to complete operating instructions. There are accompanying instructions, which are indicated by cross-references.

Observe the warning and safety instructions given there.

Prerequisites: – The crane cab is not inclined.

– The main boom is lowered to about 2°.

V à

1. Unlock the tension cylinder; ➠ Raising the gantry mast, p. 3-56.

2. Unlock the bridle straps at the collar of telescopic section III; ➠ Lock bridle pendant links at telescopic section III/remove lock, p. 3-57.

T

3. Wind rope onto the drum until the bridle straps sit close on the gantry mast.

S

4. Lower the gantry mast to 5° with the lifting cylinders.

5. Push in and secure the plastic supports; ➠ Pushing in the plastic supports, p. 3-33.

09.08.2005

S

6. Completely lower the gantry mast with the lifting cylinders.

7. Lock the rear pendant links to the main boom basic section; ➠ Removing the locking pin between the rear pendant links and the main boom basic section, p. 3-46.

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Megalift 3.6 Checklists for rigging work

8. Attach and secure rear pendant links to the gantry mast; ➠ Locking the rear pendant links to the gantry mast, p. 3-45.

F0074

9. Block the joints and secure the roller mount straps at the gantry mast; ➠ Release/secure bridle pendant links and joint locks, p. 3-43.

10. Lock the bridle to the gantry mast; ➠ Locking the bridle, p. 3-42.

T

11. Tighten the tensioning rope slightly and mechanically lock the rope winch.

12. Lock the gantry mast and the rope winch together; ➠ Establishing a lock between the gantry mast and the rope winch, p. 3-41.

13. With the ignition turned off, establish electrical connection at the rope winch; ➠ Electrical connection – Disconnecting – At the rope winch, p. 3-50.

09.08.2005

14. Disconnect the hydraulic connection of the rope winch; ➠ Hydraulic connection – Disconnecting – At the rope winch, p. 3-53.

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Megalift 3.6 Checklists for rigging work

15. Release the folding catch between the rope winch and the main boom basic section, and fold it away; ➠ Releasing the connection between the rope winch and the main boom, p. 3-39.

16. Remove the securing pins from the retainers for the rope winch plugs on the main boom; ➠ Releasing the lock between the rope winch and the main boom, p. 3-35.

F0067

17. Release the raising cylinder from the main boom; bring into transport position and lock; secure the turnbuckle at the gantry mast; ➠ Bringing the raising cylinder into the transport position, p. 3-47.

18. Bring the angle sensor into transport position; ➠ Bringing the angle sensor into transport position, p. 3-51.

F0078

19. Disconnect the hydraulic connection for the Megalift at the front by the main boom. ➠ Hydraulic connection – Disconnecting – At the raising cylinder, p. 3-53.

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20. Sling the Megalift unit at the slinging points indicated using the auxiliary crane and the rope tackle supplied (note the designation of the ropes!!); ➠ Slinging points, p. 3-30.

F0079

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Megalift 3.6 Checklists for rigging work

21. Attach guide rope to the Megalift unit, ➠ Guide rope p. 3-32.

22. Release the lock between the Megalift unit and the main boom basic section; ➠ Releasing the lock between the Megalift unit and the main boom, p. 3-36.

23. Slowly loft the Megalift unit away from the main boom with the auxiliary crane.

F0070

24. Pull out the supports and secure, and put the Megalift unit down on the separate vehicle; ➠ Pulling out the supports, p. 3-31.

25. If necessary, lash the Megalift unit to the separate vehicle for transporting; ➠ Lashing eyes, p. 3-16.

F0081

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26. If equipped with telescopic swing-away lattice extension as additional equipment, install the pertaining support on the main boom; ➠ p. 3-28.

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Megalift 3.7 Rigging work

3.7

Rigging work

3.7.1

Removing/installing the support for telescopic swing-away lattice extension The rigging work described in this section is only required if the truck crane is equipped with the additional telescopic swing-away lattice extension.

The telescopic swing-away lattice extension must be removed for operation with Megalift; ➠ GMK 6300 Swing-away lattice extension operating manual.

Furthermore, there is a support at the front right of the main boom. This is where the telescopic swing-away lattice extension engages.

– Remove the support before rigging the Megalift.

– Replace this support for operation with the telescopic swing-away lattice extension.

Removing the support

Due to the support’s tare weight (approx. 30 kg) you will need an auxililary crane for dismantling.

• Attach the sling gear (1) to the bore hole (2) and secure the support with an auxiliary crane.

• Remove the counternuts and unscrew the two adjusting screws (3) to the extent that they no longer touch the support.

• Disconnect the electrical connection (7) of the proximity switch and close the protective caps.

When releasing the lower locking screws (4) the threaded plate (5) slips down out of the retaining sheet (6). With the following steps, make sure the threaded plate does not fall down:

7

• Release the lower retaining screws (4).

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• Remove the retaining screws and take them out together with the washers.

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Megalift 3.7 Rigging work

When unscrewing the upper retaining screws (2) the distancing plate (4) is released. With the following steps, make sure the distancing plate does not fall down:

• Remove both the upper screws (2).

• Remove the retaining screws and take them out together with the washers.

• Lift the support off the main boom and set it down.

• Pull the threaded plate (3) sideweays out of the upper retaining sheet (1).

G Installing the support

Danger of injury due to falling threaded plate!

Always take the threaded plate out of the upper retaining sheet. This prevents the threaded plate from slipping out when raising the main boom, falling and injuring persons.

• Use the retaining screws and the threaded plates to attach the washers and the distancing plate to the support set down so that they will not get lost.

Due to the support’s tare weight (approx. 30 kg) you will need an auxililary crane for installation.

• Remove the retaining screws, the threaded plates, the distancing plate and the washers from the support.

• Attach the sling gear (1) to the bore hole (2) and lift the support to the main boom.

• Adjust the support in such a way that it fits close to the lower adjusting screw (6) and the left-hand adjusting screws (3).

• Insert the threaded plate (5) behind the lower retaining sheet (7).

• Remove the protective caps and insert the proximity switch into the plug connection (8).

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• Screw the retaining screws (4) into the threaded plate, do not screw completely tight.

Megalift 3.7 Rigging work

• Insert the threaded plate (6) behind the lower retaining sheet (1).

• Hold the distancing plate (5) in front of the retaining sheet (1).

• Insert the retaining screws (7) through the support and the distancing plate.

• Screw the retaining screws (7) into the threaded plate (6), do not screw completely tight.

• Screw the adjusting screws (3) down to the support, screw tight and secure with the counternuts.

• Tighten the retaining screws (4) and (7).

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• Take off the slinging tackle (2).

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Megalift 3.7 Rigging work

3.7.2

Slinging the Megalift During installation and removal, the Megalift must be tied down with the slinging tackle supplied. Only this lifting gear will ensure that the Megalift is suspended at the correct angle above the main boom.

S H

Danger of damage if incorrect lifting gear is used!

Only use the rope suspension gear supplied so that the Megalift unit will automatically be in the position required for installation, i.e. so that it hangs at an angle of 12° with the locking point to the main boom at the lowest point.

The following diagram shows a Megalift with four slinging points.

Depending on the version, there may also be three slinging points on the Megalift. The supplied rope suspension gear then has the corresponding number of ropes. Slinging points and ropes that belong together are marked with letters.

Position the hook block of the auxiliary crane above the Megalift in such a way that it is almost above the strut (3) on which the rope winch is suspended.

• Sling the Megalift unit with the supplied rope suspension gear (1) at the marked slinging points (2).

The slinging points which go together on the Megalift and the rope are indicated.

Single hook

• Hang the slinging gear (1) directly into the single hook (6).

Double hook Observe the following instructions to ensure the Megalift hangs horizontally on the longitudinal axis.

• On this sling gear, hang the supplied sling tackle (1).

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• Attach an additional sling gear (4) to the double hook (5).

Megalift 3.7 Rigging work

3.7.3

Pushing in/pulling out the supports

Pushing in the supports

To push in the supports, you must first raise the Megalift with an auxiliary crane; you can then push in and secure all four supports.

• Loosen the retaining pin (2) and remove the pins (3) from the supports.

• Push the supports (1) upwards.

• Insert the pins into the bores again and secure them with the retaining pin.

Pulling out the supports

Danger of injury through improper handling!

Hold the lower part of the supports firmly when pulling out the pins, as you may otherwise be injured by falling supports.

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G

When pulling out the supports, you must first pull out and secure the supports on the lower side. The second step is to set down the Megalift on the lower lying supports and then pull the other supports out.

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Megalift 3.7 Rigging work

• Loosen the retaining pin (2), slightly raise the supports (1) and remove the pins (3) from the supports.

• Lower the supports (1) until the bores holes in the supports and the guide tubes align.

• Insert the pins into the bores again and secure them with the retaining pin.

• Set the Megalift down on the lower lying supports.

• Lower the higher supports as described above.

• Set down the Megalift on the separate vehicle.

3.7.4

Guide rope

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• Attach the guide rope to one of the lashing eyes (2) or (3), left or right at the foot of the Megalift (1), so that the gantry mast which is suspended on the auxiliary crane can be positioned better above its locking position on the main boom, and/or so that it can be secured on the way to the separate vehicle.

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Megalift 3.7 Rigging work

3.7.5

Pulling out/pushing in the plastic supports

Pulling out the plastic supports

The plastic supports at the top end of the Megalift unit must always be in the lowest position when the Megalift is mounted.

• Release the retaining pin (2), hold the plastic supports (3) at the grip (1) and pull out the pin (4).

• Pull out the plastic supports and lock them into the upper bore hole.

• Secure the pin (4) using the retaining pin (2).

Pushing in the plastic supports

The plastic supports at the top end of the Megalift unit must always be in the top position while the Megalift is being mounted or dismantled.

• Release the retaining pin (2), hold the plastic supports (3) at the grip (1) and pull out the pin (4).

• Pull the plastic supports up and lock them into the lower bore.

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• Secure the pin (4) using the retaining pin (2).

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Megalift 3.7 Rigging work

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Megalift 3.7 Rigging work

3.7.6

Establishing/releasing a lock between the rope winch and the main boom On the right-hand side of the main boom, there are three pins in the retainers (1) for locking the rope winch and the main boom.

The lock must be released before the rope winch is suspended during installation and/or before it is lifted off the main boom together with the gantry mast during removal.

After the rope winch is suspended, the lock must be established again in order to secure the winch to the main boom.

Releasing the lock

• Press the securing pins in against the spring pressure and turn them about 90° so that the plugs point upwards.

• Pull out the securing pins and set them down on the carrier.

F0083

Establishing a lock

• Press the securing pins in against the spring pressure and turn the about 90° so that the plugs point sideways.

• Let go of the securing pins: they are now secured in the retainer.

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F0084

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Megalift 3.7 Rigging work

3.7.7

Establishing/releasing a lock between the Megalift and the main boom The Megalift is bolted to the main boom left and right on the basic section. Both pins required are found in the holders on the gantry mast.

Locking the Megalift

• Lift the Megalift unit over the main boom with an auxiliary crane in such a way that the straps (1) engage in the fork elements (2) on both sides.

• Position the gantry mast in such a way that the locking positions align.

• Release the retaining pins and remove the pins (3) on both sides from the brackets (4).

• Lock the Megalift to the main boom and then secure the pins with the retaining pins.

Releasing the lock

Danger of damage to the Megalift and the main boom!

The centre of gravity of the Megalift block is not on the longitudinal axis.

For this reason, position the hook block of the auxiliary crane above the Megalift in such a way that it is almost above the strut on which the rope winch is suspended. Otherwise the Megalift unit will tilt at the locking points on the main boom when raised, and could destroy them.

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S

Before pulling out the pins, the Megalift must be slung to an auxiliary crane with the rope suspension gear supplied, and raised to about 12°.

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Megalift 3.7 Rigging work

• Remove the retaining pins from the pins (1).

• Remove the pins from the locking positions (2).

• Insert the pins into the holders (4) on the Megalift and secure them with retaining pins.

• Lift the Megalift (3) from the main boom with the auxiliary crane.

3.7.8

Lowering the Megalift onto the main boom

Before lowering

• Remove the retaining pins and pull the pins out of the locking points on the main boom.

• Check whether the securing pins for the rope winch have been pulled out of the retainers on the main boom.

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When lowering

G S

Danger of injury from unfastened rope winch!

When lowering the Megalift unit, make sure that the plugs of the rope winch thread through the retainers in the main boom. Otherwise, the rope winch will fall when released from the Megalift.

Danger of damage to the support cylinder!

When lowering the Megalift unit, make sure that the rear pendant links thread through the bracket at the foot of the main boom basic section, as the rear pendant links could otherwise bend.

• Make sure that the plugs (1) on the rope winch thread through the retainers on the main boom.

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• Make sure that the rear pendant links (2) thread through the fork elements (1).

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3.7.9

Establishing/releasing a connection between the rope winch and the main boom

Connecting

The rear section of the rope winch must be connected to the main boom basic section by means of an adjustable lock, so that the winch sits fast on the main boom during tightening and does not rotate.

• Release the retaining pin and remove the pins (3) from the holder (4).

• Fold down the metal bar (2) and lock it to the rope winch with the holder (1).

• Secure the pin (3) using the retaining pin.

Disconnecting

When the Megalift unit is removed from the main boom, the connection between the rope winch and the main boom must be broken again.

• Release the retaining pin and remove the pins (3) from the holder (1) on the rope winch.

• Fold down the metal bar (2) and lock it to the main boom via the holder (4).

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• Secure the pin (3) using the retaining pin.

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3.7.10

Establishing/releasing a lock between the gantry mast and the rope winch The rope winch is secured to the transport mounting by four pins, two each on the left and on the right. Each pair of pins is secured with an additional safety element (a retaining pin and a retaining rod). The retaining pin secures the retaining rod on the transport mounting and in the bracket on the winch.

Releasing the lock

When the Megalift is erected, the rope winch must remain fixed at the main boom. For this reason, the rope winch must be released from the gantry mast.

• Remove the safety elements (2) and (3) and pull the pins (1) from the transport mounting (5).

• Insert the pins (1) into the holder (4) on the rope winch.

• Secure the pins (1) using the safety elements (2) and (3).

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• Also release the connection on the other side of the rope winch.

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Establishing a lock

For transportation, the rope winch must be connected to the set-down Megalift again. The four pins are in the retainers on the rope winch.

• Remove the safety elements (2) and (3) and pull the pins (1) from the holders (4).

• Insert the pins (1) into the transport mounting (5).

• Secure the pins (1) using the safety elements (2) and (3).

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• Also establish the lock on the other side of the rope winch.

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3.7.11

Releasing/locking the bridle The bridle, which deflects the gantry mast, is secured to the Megalift by two pins left and right during transportation.

Releasing the bridle

The pins must be released before the Megalift unit is raised.

• Remove the retaining pins (2).

• Remove pins (1) from the retainers (3) and secure them in the holders (4).

• Secure the pins in place using the retaining pins.

Locking the bridle

For transportation, the bridle must be secured to the Megalift with two pins right and left.

• Remove the retaining pins (2).

• Remove pins (1) from the holders (4) and insert them into the retainers (3).

• Secure the pins into place using the retaining pins.

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3.7.12

Releasing/securing the bridle pendant links

Releasing

Before raising the gantry mast, release the bridle pendant links and the joint lock.

Releasing the bridle pendant link Release the retaining pins (5) and take them out of the holder (4).

• Keep the retaining pins for crane operation.

• Release the second bridle pendant link as well Release the joint locks

• Release the retaining pin and pull the pins (2) out of the joint between the bridle strap (3) and the bridle pendant links (1).

• Release the second joint lock as well

H Securing

You will need the pins (2) after having raised the gantry mast to attach the bridle straps to telescopic section III.

After setting down the gantry mast you must secure the bridle pendant links and lock the joints.

Securing the bridle pendant links • Check whether the bridle pendant links are in the holder (4).

• Insert the retaining pin (5) in the bracket (4).

• Secure the second bridle pendant link as well Locking the joints

• Insert the pin (2) into the joint between the bridle strap (3) and the bridle linkage (1).

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• Lock the second joint as well.

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3.7.13

Establishing/releasing a lock between the rear pendant links and the gantry mast

F0011

For transportation, the rear pendant links are attached to the Megalift at six points: – externally, at the head of the Megalift – internally, at the head of the Megalift and – just in front of the bridle

Releasing the rear pendant links

The rear pendant links must be released from the gantry mast so that the erected Megalift can be tensioned at a later point.

Release the rear pendant links when the gantry mast is set down.

• Remove the retaining pins from all six pins.

• Release the rear pendant links from the Megalift by pulling the pins from the bearing points.

• Insert the retaining pins into the safety bolts and keep the safety bolts in a safe place (e.g. in thr storage compartment) to prevent them from falling down or getting lost during crane operation.

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G

Danger of injury due to falling safety bolts!

Always keep the safety bolts in a safe place.

If you leave the safety bolts on the main boom, they will fall down during raising and may injure persons or damage parts of the truck crane.

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Attaching the rear pendant links

F0011

For transportation, the rear pendant links must be attached to the gantry mast. The rear pendant links are released when the gantry mast is set down and after the locking pin between rear pendant links and main boom basic section has been removed.

• Insert the safety bolts in all six bearing points.

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Secure the safety bolts into place using the retaining pins.

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3.7.14

Establishing/releasing the lock between the rear pendant links and the main boom basic section

Establishing the lock

When installing the Megalift, a rear pendant link is locked on each side at the foot of the main boom basic section.

• Insert the pins (1) and secure them with retaining pins (2).

Releasing the lock

When removing the Megalift, each of the rear pendant links on each side at the foot of the main boom basic section must be released.

• Release the retaining pins (2) and pull out the pins (1).

• Raise the rear pendant links slightly and put the pins into the locking points again.

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• Secure the pins into place using the retaining pins.

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3.7.15

Working position/transport position of the raising cylinder The Megalift is raised with the help of two hydraulic cylinders (raising cylinders).

Bringing the raising cylinder into working position

Both cylinders are brought into position with the turnbuckles during installation and then locked left and right onto the main boom.

• Remove the retaining pin.

• Pull the pin (1) from the free end of the raising cylinder (2).

• Rotate the turnbuckle (3) until the raising cylinder is in the locking position (5) on the main boom.

• Insert pin (1) and secure it with the retaining pin.

• Release the turnbuckle (3) from the raising cylinder and attach it to the strap (4) on the Megalift.

• Repeat the procedure for the raising cylinder on the other side.

Bringing the raising cylinder into transport position

When removing, the raising cylinders are released from the main boom and secured to the Megalift again.

• Release the turnbuckle (3) from the strap (4) on the Megalift and attach it to the raising cylinder (2).

• Loosen the safety device and remove the pin (1) from the locking point (5) on the main boom.

• Rotate the turnbuckle (3) until the raising cylinder is as high as it can be.

• Insert the pin (1) into the free end of the raising cylinder and secure it with the retaining pin.

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• Repeat the procedure for the raising cylinder on the other side.

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3.7.16

Establishing/breaking the electrical connection The electrical connection points are at two different locations. One is on the rope winch, the other on the front right of the main boom.

S

Risk of malfunction in the superstructure electronics!

Always turn off the ignition on the superstructure before you establish or break the electrical connection. In this way you prevent malfunctions in the superstructure electronics and corresponding error messages in the crane operation which follows.

Establishing On the rope winch

• Remove the bridging plug (5) from the socket (3) and insert it in the dummy socket (4).

• Remove the plug (2) from the dummy socket (1) and insert it in the socket (3).

• Remove the plug (8) from the dummy socket (10) and insert it in the socket (9).

Next, the plugs in the sockets (7) and (11) need to be swapped around.

• Remove the plug (12) from the socket (11).

• Remove the plug (6) from the socket (7).

• Insert the plug (12) into the socket (7).

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• Insert the plug (6) into the socket (11).

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Front right of the main boom

• Open the socket (2).

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

• Close the socket (1).

Breaking Front right of the main boom

• Open the socket (1).

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

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• Close the socket (2).

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On the rope winch

• Remove the plug (2) from the socket (3) and insert it into the dummy socket (1).

• Remove the bridging plug (5) from the dummy socket (4) and insert it in the sokket (3).

• Remove the plug (8) from the socket (9) and insert it into the dummy socket (10).

Next, the plugs in the sockets (7) and (11) need to be swapped around.

• Remove the plug (12) from the socket (7).

• Remove the plug (6) from the socket (11).

• Insert the plug (12) into the socket (11).

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• Insert the plug (6) into the socket (7).

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3.7.17

Working position/transport position of the angle sensor The current angle of the Megalift stand to the main boom is transmitted to the SLI via the angle sensor at the foot of the Megalift stand.

During installation, the angle sensor must be moved into the working position; during removal, the angle sensor is moved into the transport position.

Bringing angle sensor into working position

• Remove the retaining pin (1) and rotate the cap nut (2) from the holder (3).

• Pull the folding bracket (4) from the holder (3) and fold it upwards towards the holder (5).

• Press the folding bracket onto the holder (5).

• Screw on the cap nut and secure it with the retaining pin (1).

Bringing the angle sensor into transport position

• Remove the retaining pin (1) and rotate the cap nut (2) from the holder (5).

• Pull the folding bracket (4) from the holder (5) and fold it downwards towards the holder (3).

• Press the folding bracket onto the holder (3).

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• Screw on the cap nut and secure it with the retaining pin (1).

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3.7.18

Establishing/breaking the hydraulic connection The hydraulic connection points are at two different locations. One is on the raising cylinder (on the right of the main boom), the other is on the rope winch.

Establishing At the raising cylinder

• Remove the cover caps from the quick couplings on the hydraulic connections (1) and the hydraulic hoses (2).

• Take the hydraulic hoses from the holder (3) on the Megalift.

Corresponding plugs and couplings are marked in color.

• Connect the quick couplings of the hydraulic connections and the hydraulic hoses.

On the rope winch The plugs are divided into two groups of three. The plugs (1) and the couplings (2) are marked. Correct allocation is ensured by the same colour and number of markings.

• Remove the cover caps from the quick couplings on the hydraulic connections (1) and the hydraulic hoses (2).

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• Connect the quick couplings of the hydraulic connections and the hydraulic hoses.

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Breaking At the raising cylinder

• Detach the quick couplings and pull the hydraulic hoses (2) from the hydraulic connections (1).

• Suspend the hydraulic hoses in the holder (3) on the Megalift.

• Close the quick couplings of the hydraulic connections and the hydraulic hoses with the cover caps.

On the rope winch

• Detach the quick couplings and pull the hydraulic hoses from the hydraulic connections (1).

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• Close the quick couplings of the hydraulic connections and the hydraulic hoses with the cover caps.

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3.7.19

G

Reeving the hoist rope Risk of accidents due to falling parts.

Always secure the safety rollers and rods with retaining pins.

This prevents elements from coming loose, falling down and injuring people.

For operation with the Megalift, the hoist rope is always guided between the Megalift and the main boom. To prevent damage to the Megalift and the hoist rope, there are two sheaves for the main hoist rope and the auxiliary hoist rope on the underside of the Megalift.

Rope guide on the main boom

• Remove the retaining pin, pull out the shaft (3) of the small sheave (2) and remove the sheave.

• Guide the hoist rope (1) between the main boom and the gantry mast.

• Install the small sheave in such a way that the hoist rope runs between the two sheaves.

• Place the shaft through the small sheave and secure with the retaining pin.

• Loosen the retaining pins (1) and remove the rope holding rods (4) from the bore holes on the boom head.

• Reel off the hoist rope and place it over the sheaves (6) and (5) on the boom head.

• Reeve the hoist rope. If you reeve the hoist rope several times, observe the information in the chapter in GMK 6300 Operating manual – Reeve hoist rope.

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• Insert the holding rods (4) back into the bore holes on the boom head.

Secure the retaining rods into place using the retaining pins.

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• Secure the rope end clamp to the hook block or the attachment plate on the head section, depending on the reeving.

• Check that the locking on the lifting limit switch has been lifted; ➠ GMK 6300 Operating manual – Lifting limit switch at the main boom.

• Suspend the lifting limit switch weight and place it at the hoist rope; ➠ GMK 6300 Operating instructions – Suspending and fastening the lifting limit switch weight.

• Repeat the procedure for the auxiliary hoist rope if necessary.

3.7.20

Raising and setting down the gantry mast

Raising the gantry mast

Before the Megalift is tensioned, the gantry mast is raised. This is done via the operating panel in the crane cab.

The following conditions must first be met: – The rear pendant links have been released from the Megalift.

– The turnbuckle between the transport mounting and the rope winch is released.

– The bridle is released from the Megalift.

– The rear pendant links are locked to the main boom basic section.

– The rope winch is disconnected from the Megalift.

– The display on the ECOS is switched to the Megalift menu.

Information regarding the Megalift can be called up via the ECOS display in the crane cab. For this to happen, the Megalift must be installed and connected and the central on/off switch on the operating panel of the Megalift control system must be switched on.

üü

• Press the function button F3 twice.

The monitor mask Megalift operating values will be displayed.

Das Menü The Megalift operating values menu consists of the following subsidiary items: – Megalift angle – Length of tension cylinder

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The current values are shown in the display.

V i

• Press down and hold the Lock/unlock winch rocker switch.

The tension cylinder is unlocked when the Winch unlocked indicator lamp lights up.

• Place on the hoist rope or hoist ropes, depending on the operating conditions. For more information see ➠ Rope guide on the main boom, p. 3-54.

• For reeving the hook block, see the chapter GMK 6300 Operating instructions – Hoist rope reeving.

s

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S S S Setting down the gantry mast

Danger of damage to the rear pendant links!

When raising, make sure that the rear pendant links open properly. Stop the raising movement immediately if this is not the case, as the rear pendant links could otherwise bend or break.

Risk of damage to the collars on the telescopic sections!

The bridle is lowered when the gantry mast is raised.

Counteract this movement by winding up the rope winch. This way you will prevent the bridle pendant links from sinking right down onto the main boom and possibly damaging the collars.

• Press up and hold the Raise/lower gantry mast rocker switch until the Gantry mast in 90° position indicator lamp lights up.

Before removing the Megalift or working with the main boom and installed Megalift, the gantry mast has to be set down. This is done via the operating panel in the crane cab.

Information regarding the Megalift can be called up via the ECOS display in the crane cab.

üü

• Press the function button F3 twice.

The monitor mask Megalift operating values will be displayed.

The Operating values menu consists of the following subsidiary items: – Megalift angle – length of tension cylinder

V i

S S 3 - 56

When the Megalift is tensioned, pressing the “Lock/unlock winch” rocker switch simultaneously relieves the Megalift.

• Press down and hold the Lock/unlock winch rocker switch.

The tension cylinder is unlocked when the Winch unlocked indicator lamp lights up.

Danger of damage to the rear pendant links!

When setting down, make sure that the rear pendant links close up properly. Stop the setting-down movement immediately if this is not the case, as the rear pendant links could otherwise bend or break.

• Press down and hold the Raise/lower gantry mast rocker switch until the Megalift is completely set down.

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H

The current values are shown in the display.

Megalift 3.7 Rigging work

3.7.21

Lock/release lock of bridle pendant links to telescopic section III

Locking

To mount the Megalift, the bridle pendant links are locked to the collar of telescopic section III.

• You will need the pins you removed from the bores (4) when you released the joint blocks.

• Guide the bridle straps (1) to the head of telescopic section III. To do so you must unwind the rope winch.

• Place the bridle straps so that they align with the the brackets (3).

• Lock the bridle straps with the pins (2).

• Secure the pins into place using the retaining pins.

Releasing the lock

To disassemble the Megalift, remove the lock between the bridle pendant links and telescopic section III.

• Remove the retaining pins and pull the pins (2) out of the bridle straps (1) and the brackets (3).

• Guide the bridle straps (1) to the gantry mast. To do so you must wind up the rope winch.

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After having set down the gantry mast, the pins (2) are inserted into the the bores (4) to lock the joints and secured with retaining pins.

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3.7.22

Pre-tensioning the Megalift When the Megalift is to be pre-tensioned, the following conditions must be met: – The Megalift must be completely rigged.

– The Megalift control system at the control unit in the crane cab must be activated.

– All telescopic sections must be locked.

– The Megalift in 90° position indicator lamp must light up.

– The appropriate rigging code must be set at the SLI. – Apart from the hook block, there must be no load on the hoist rope.

T

H H

• To pre-tension, press up the Wind/unwind winch rocker switch until the winch stops moving.

Pre-tensioning occurs purely via the power of the rope winch.

For operation, the Megalift must be tensioned. For this, a hydraulic cylinder locks itself to the rope winch and continues to rotate the rope winch until the pre-tensioning force has been achieved.

Work with the Megalift is only possible with particular main boom telescoping statuses. If you wish to work with a particular telescoping, you must first telescope and then tension.

If you wish to change the telescoping during operation, you must first relieve the Megalift, then telescope and in conclusion tension again.

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Further information on working with the Megalift; ➠ Operating with main boom and Megalift, p. 4-1.

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Megalift 3.8 Maintenance plans

3.8

3.8.1

H

Maintenance plans All general notes, safety rules and information on environmental protection contained in the maintenance manual of the GMK 6300, Chapters 1 and 2, apply when carrying out this maintenance work.

The following maintenance plans apply in addition to the maintenance plans of the same name in the GMK 6300 maintenance manual.

The same abbreviations are used as in the GMK 6300 maintenance manual (e.g. Bh = operating hours)

Maintenance plan D: daily

D Maintenance work on the SUPERSTRUCTURE: daily

Oil/lubricant Amount (l)/ Quantity

Designation

Megalift (additional equipment) – Position of the rope on winch drum and sheaves check; ➠ 3.10.1, p. 3-63.

3.8.2

Maintenance plan W: weekly

W Maintenance work on the SUPERSTRUCTURE: weekly

Oil/lubricant Amount (l)/ Quantity

Designation

Megalift (additional equipment) – Check the winch gear for tightness; ➠ 3.10.2, p. 3-64.

– Check the condition of the guy rope1); ➠ 3.10.4, p. 3-65.

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– Check the oil level at the winch gear; ➠ 3.10.3, p. 3-64.

1)

E3

If the Megalift is in storage, the condition checks are only necessary every three months.

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3.8.3

M 3 maintenance plan: every 3 months/after 300 op. hours

M3 Maintenance work on the SUPERSTRUCTURE: every 3 months/ after 300 op. hours

Oil/lubricant Amount (l)/ Quantity

Designation

2

K

Megalift (additional equipment) – Lubricate the winch gear; ➠ 3.10.5, p. 3-69.

3.8.4

M 12 maintenance plan: every 12 months/after 1000 op. hours

M 12 Maintenance work on the SUPERSTRUCTURE: every 12 months/ after 1000 op. hours

Oil/lubricant Amount (l)/ Quantity

Designation

1.5

E3

Megalift (additional equipment) – Oil change at the winch gear1); ➠ 3.10.6, p. 3-70.

Carry out at least once a year

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1)

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Megalift 3.9 Lubrication chart

3.9

H

Lubrication chart The lubricants listed in the following table are to be used for the maintenance of the Megalift. If the table of lubricants in the Maintenance manual of the GMK 6300 contains other lubricants under the same designation, use only those lubricants in this table for the Megalift.

Lubricating point

Type of lubrication

Name according to DIN 51502

E3

Gearbox

Circulatory lubrication

K

Roller bearing

Grease applied during repairs

Specification Classification

Lubricant type Viscosity range

C - LPF

API GL 5 MIL-L 3105B

SAE 90 ISO - VG 220

KP - L2K

DIN 51825

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Designation

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Megalift 3.9 Lubrication chart

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Megalift 3.10 Maintenance work

3.10

Maintenance work

3.10.1

Checking the position of the rope on the winch drum

G

D

Danger of accidents due to turning rope drum.

Keep yourself and other people away from the turning rope drum. If you take hold of the turning rope drum, your fingers and hands could be crushed between the rope drum and frame or get caught and drawn in by the turning drum.

• Check the position of the rope on the winch drum of the Megalift (additional equipment).

• Support the truck crane with the outrigger span 8.70 m x 8.50 m.

• Raise the gantry mast.

• Extend the main boom by approx. 4 m.

• Monitor the rotating rope drum and the wound-off rope.

– The rope must be wound evenly on the drum.

– The turns on the drum must all be at an equal distance of 0 to 2 mm.

– The cross-over points must be at an angle of approx. 180° to each other.

H

• Retract the main boom again.

The upper layer of rope lies over the lower layer at the cross-over points.

• Check the position of the winch rope on the sheaves at the bridle.

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• Check the sheaves for damage and wear, and check that they run freely.

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Megalift 3.10 Maintenance work

3.10.2

W

Checking the winch gearbox for tightness • Make a visual inspection for leaks.

• If hydraulic oil or gear oil has been lost, check the oil levels and top up if necessary.

If damage cannot be rectified immediately or further damage is likely:

• Inform CraneCARE or your repair crew.

3.10.3

Checking the oil level of the winch gearbox

W

The standpipe used to read the oil level in the winch gear is located on the right-hand side of the winch.

• Place the retracted main boom in the boom support.

• Check the oil level of the winch gear at the standpipe (3). The oil level must be between the MAX. and MIN. marks (4).

If the oil level is too low:

• Unscrew the upper sealing screw (1) and remove the connecting hose (2) from the standpipe.

• Top up oil via the standpipe (3).

Use only oil specified in the Maintenance plan, p. 3-59

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• Replace the sealing rings of the upper screw plug and screw the upper hose back on.

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3.10.4

W

Checking the condition of the guy rope

The Megalift must be installed on the main boom. The main boom is resting on the boom support.

The rope, the sheaves and the rope end fittings need to be checked.

• Completely unwind the guy rope and check the entire length of the rope exit and the rope. The criteria for assessing the condition of the rope or damage to the rope can be found in the GMK 6300 Maintenance manual, in the section Assessing the condition of the hoist ropes of the chapter Hoist ropes.

Rope

H

The following table indicates at what amount of wire breaks the rope must be changed.

These values only apply to the original rope!

Supporting outer wires

201 - 220

G S 09.08.2005

Sheaves

Crosslay rope (diameter 33 mm) on 6 x d (198 mm length)

on 30 x d (990 mm length)

9

18

Risk of accidents from falling loads!

The guy rope must not be shortened. If the rope is shortened, there will no longer be 5 safety turns on the rope drum when the main boom is fully extended. Without the safety turns, the guy rope will slip from the rope drum during operation. Damage to the main boom and dropping of the load could result.

Danger of damage to the Megalift!

Use only a replacement guy rope which has the same technical specifications as the defective rope, or an original replacement rope.

If it is necessary to change the rope, refer to ➠ Changing the rope in this section.

• Check the sheaves for breaks. There must be no drag lines in the grooves. The rollers must run freely.

• Damaged sheaves must be replaced immediately.

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Megalift 3.10 Maintenance work

Rope end fitting

The guy rope is fastened in the rope drum with a clamp. On the gantry mast, the end fitting takes the form of a metal clamped splice.

• Release the metal clamped splice. To do this, unscrew the screw (2) and remove the pins (1).

• Check the metal clamped splice and the rope near the clamp and around the pins for corrosion and deformation.

• Damaged sheaves must be replaced immediately.

• Reattach the metal clamped splice with the pin. Replace the screw and tighten it.

(Tightening torque 310 Nm).

The clamp in the rope drum is accessible between the main boom and the winch housing. On the back of the winch housing there is an assembly aperture, through which the clamping screws are accessible. In order to reach all 15 clamping screws, the winch must be turned.

Risk of accidents from unintentional rotation of the rope drum!

Make sure that the crane engine is switched off when you are working at the rope drum. The rotating rope drum can inflict serious crushing injuries!

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G G

Risk of accidents from rotating rope drum!

When the winch is to be turned, remove the torque wrench from the assembly aperture and step back from the winch. You could be injured by flying tools or by the rotating rope drum.

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Megalift 3.10 Maintenance work

• Remove both counterscrews (1).

• Check the tightening torque of the 15 clamping screws (2) (tightening torque 300 Nm).

• Replace the counterscrews.

Changing the guy rope

G G

The main boom is resting in the boom support. The damaged guy rope is unwound.

Risk of accidents from rotating rope drum!

When the winch is to be turned, remove the torque wrench from the assembly aperture and step back from the winch. You could be injured by flying tools or by the rotating rope drum.

Risk of accidents from unintentional rotation of the rope drum!

Make sure that the crane engine is switched off when you are working at the rope drum. The rotating rope drum can inflict serious crushing injuries!

• Release the guy rope clamp on the back of the rope drum. The drum must be turned to do this.

• Pull the rope out of the clamping channel.

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The new rope must be pushed in up to the end of the clamping channel.

For this purpose the clamping length is marked.

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Megalift 3.10 Maintenance work

S

Risk of accidents from slipping rope clamp!

Always push the rope up to the designated clamping length in the clamping channel. If the clamping length is too short, the rope may slip out of the drum. Damage to the main boom and dropping of the load could result.

• Mark the clamping length of ca. 700 mm on the rope.

• Push the rope into the clamping channel up to the marked clamping length.

• Tighten the 15 clamping screws (2) (tightening torque: 300 Nm).

• Wind up the new rope.

• Check the tightening torque of the clamping screws again.

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• Tighten the counterscrews (1).

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Megalift 3.10 Maintenance work

3.10.5

Lubricating the winch gearbox

M3

The winch gear is lubricated via lubricating nipples (1) and (2) on the front and back of the winch.

• Remove old grease and dirt from the lubricating nipples.

• Use a grease gun to apply grease to the lubricating nipples.

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• Use only lubricating grease specified in the Maintenance plan, p. 3-60.

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Megalift 3.10 Maintenance work

3.10.6

M 12

Oil change on the winch gearbox Use only oil specified in the Maintenance plan, p. 3-60.

O H

Pollution warning!

Always use oil collection containers which are oil-resistant.

Wipe up spilled oil immediately.

By examining the old oil for abrasion particles, damage can be recognised at an early stage. Further information on checking the oil can be found in the corresponding section in the chapter “Hoisting gear” of the GMK 6300 Maintenance manual.

Prerequisites: – The Megalift must be installed on the main boom. The main boom must then be in horizontal position. or – The Megalift is in transport position.

• Place oil collection containers under the oil drain plugs (3) (capacity: more that 2 litres).

• Loosen the upper screw plug (1) on the standpipe.

• Unscrew the oil drain plug (3) and let the oil flow into the collection container.

• Retighten the oil drain plug when the oil has completely discharged. Replace the sealing ring.

• Fill the oil as specified in the Maintenance plan through the upper opening of the standpipe (1), up to the MAX. mark (2).

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• Renew the sealing ring on the upper screw plug and tighten the drain plug.

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________________________________________________________________________________________

4

4

Operation with main boom and Megalift

4.1

Non-braced operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

4.1.1 4.1.2 4.1.3 4.1.4

4.2 4.2.1 4.2.2 4.2.3

4.3 4.3.1

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift gantry mast to 20° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unlocking the winch and breaking the electrical connection . . . . . . . . . .

Operation with non-braced Megalift . . . . . . . . . . . . . . . . . . . . . . .

4444-

1 2 3 5

Braced operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising and bracing the gantry mast . . . . . . . . . . . . . . . . . . . . . .

Operation with braced Megalift . . . . . . . . . . . . . . . . . . . . . . . . .

4- 7 4- 8 4 - 11

Axle loads when moving with rigged crane . . . . . . . . . . . . . . . 4 - 13 Position of the boom and the Megalift . . . . . . . . . . . . . . . . . . . . . .

4 - 14

Malfunctions on the Megalift . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17

4.5

Turning loads with the auxiliary single-sheave boom top and Megalift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19

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4.4

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Operating manual for Megalift GMK 6300

Operation with main boom and Megalift 4.1 Non-braced operation

4

Operation with main boom and Megalift There are two basic operating modes for main boom operation with the Megalift.

Firstly, there is non-braced operation, where the Megalift is rigged on the main boom, but is neither completely erected nor braced for operation; ➠ Non-braced operation, p. 4-1.

Secondly, there is braced operation, in other words the actual operation with rigged and braced Megalift; ➠ Braced operation, p. 4-7.

4.1

Non-braced operation For operation with main boom and non-braced Megalift, the gantry mast must be raised to 20° with the raising cylinders so that the hoist ropes used, which are guided under the gantry mast, do not become damaged.

4.1.1

Prerequisites For operation with non-braced Megalift, the following conditions must be met: – The truck must be on outriggers corresponding to the outrigger span stated in the Lifting capacity table.

– The appropriate counterweight stated in the Lifting capacity table must be rigged.

– The Megalift must be installed.

– The roller mount linkage must be released from telescopic section III and secured on the gantry mast.

– The Megalift must be electrically and hydraulically connected.

– The Megalift control system must be switched on.

– The hoist rope must be in place and the hook block reeved.

– Hoist the gantry mast to 20° ; ➠ Raising the gantry mast, p. 4-2,

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– Lock the winch and break the electrical connection for Megalift control; ➠ Locking the winch and breaking the electrical connection, p. 4-3.

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4-1

Operation with main boom and Megalift 4.1 Non-braced operation

4.1.2

Lift gantry mast to 20° • Check whether the requirements for raising the gantry mast have been met; ➠ Raising the gantry mast, p. 3-55.

When raising the gantry mast, you can set the Crane control display in the crane cab to show the angle of the gantry mast to the main boom.

. üü

• Press down the Megalift control system rocker switch to activate the Megalift control system.

• Press the function button F3 twice.

The Megalift operating values menu will be displayed.

The Megalift operating values menu consists of the following subsidiary items: – Length of the tension cylinder, – Megalift angle, – Pre-tightening force (set and actual values).

The current values are shown in the display.

V à

• Press down and hold the Lock/unlock winch rocker switch.

The tension cylinder is unlocked when the Winch unlocked indicator lamp lights up.

In the Megalift operating values menu, the value for the length of the tension cylinder is shown in 0 %.

MEGALIFT STATUS l [%] :

0

α [°] :

F [kN] :

0

(40)

Danger of damage to the end-tensioning posts!

When raising, make sure that the end-tensioning posts open properly.

Stop the raising movement immediately if this is not the case, as the endtensioning posts could otherwise bend or break.

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S

0

4-2

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Operating manual for Megalift GMK 6300

Operation with main boom and Megalift 4.1 Non-braced operation

S

• Press up the rocker switch Raise/lower gantry mast.

• Hold the Raise/lower gantry mast rocker switch until an angle of 20° is shown in the Megalift operating values menu.

MEGALIFT

STATUS l [%] :

0

α [°] :

F [kN] :

0

(40)

4.1.3

20

Unlocking the winch and breaking the electrical connection Lock the winch and break the electrical connection of the Megalift control system prior to crane operation with untensioned Megalift.

Locking the winch

S

Risk of damage to the rope on the winch!

Always lock the winch prior to untentioned operation. This way you will prevent the winch from turning and causing slack rope. Slack rope may cause load slippings and the destruction of the rope during untensioned operation.

• Press down and hold the Lock/unlock winch rocker switch.

The tension cylinder is unlocked when the Winch unlocked indicator lamp lights up.

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V â

The winch must be locked during untensioned operation to prevent the rope from unintentionally unwinding.

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4-3

Operation with main boom and Megalift 4.1 Non-braced operation

Breaking the electrical connection

The winch must be locked for untensioned operation. The Megalift control blocks telescoping if the winch is locked. You must therefore break the electrical connection to the Megalift control. This way the control system does not register the locked status and telescoping is enabled.

• Remove the plug (2) from the socket (3) and insert it into the dummy socket on the lattice extension (1).

• Remove the bridging plug (5) from the dummy socket (4) and insert it in the socket (3).

• Close the cover cap of the dummy socket (4).

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Do not remove the plugs from the sockets (6), (7) or (8). If you remove these plugs the SLI will not indicate the reduced loads.

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Operation with main boom and Megalift 4.1 Non-braced operation

4.1.4

Operation with non-braced Megalift For operation with the non-braced Megalift, you must set an SLI code for main boom operation as stated in the Lifting capacity table.

S H

Danger of accidents with improperly rigged truck crane The mobile crane may only be operated with non-braced Megalift when the gantry mast is in the 20° position. In all other positions, the hoist ropes would become damaged, or the load distribution on the truck crane would not be secured.

If the Megalift is installed but not braced during main boom operation, the values for main boom operation given in the lifting capacity table will be reduced and the SLI will correspondingly switch off earlier.

The reduced values are shown on the SLI display Maximum Load if you break the electrical connection to the Megalift control only; ➠ Breaking the electrical connection, p. 4-4 The relevant formulas and examples for calculating these values during applications engineering can be found in the Lifting capacity tables.

09.08.2005

Truck crane operation with non-braced Megalift proceeds as described in the chapter Working with the crane and main boom in the GMK 6300 Operating instructions.

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4-5

Operation with main boom and Megalift 4.1 Non-braced operation

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4-6

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Operating manual for Megalift GMK 6300

Operation with main boom and Megalift 4.2 Braced operation

4.2

Braced operation For main boom operation with braced Megalift, the gantry mast must be raised to the 90° position and braced in this position.

Before the gantry mast can be tensioned, the main boom must be brought to the respective telescope status and derricked to the respective tensioning angle.

4.2.1

Prerequisites For operation with braced Megalift, the following conditions must be met: – The truck must be on outriggers corresponding to the outrigger span stated in the Lifting capacity table.

– The appropriate counterweight stated in the Lifting capacity table must be rigged.

– The Megalift needs to be installed and connected hydraulically and electrically (electrically only if an untensioned operation preceded), – The Megalift control system must be switched on.

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– The hoist rope must be in place and the hook block reeved.

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4-7

Operation with main boom and Megalift 4.2 Braced operation

4.2.2

Raising and bracing the gantry mast

Raising the gantry mast

• Check whether the requirements for raising the gantry mast have been met; ➠ Raising the gantry mast, p. 3-55.

When raising the gantry mast, you can set the Crane control display in the crane cab to show the angle of the gantry mast to the main boom.

. üü

• Press down the Megalift control system rocker switch to activate the Megalift control system.

• Press the function button F3 twice.

The Megalift operating values menu will be displayed.

The Megalift operating values menu consists of the following subsidiary items: – Length of the tension cylinder, – Megalift angle, – Pre-tightening force (set and actual values).

The current values are shown in the display.

V à

• Press down and hold the Lock/unlock winch rocker switch.

The tension cylinder is unlocked when the Winch unlocked indicator lamp lights up.

In the Megalift operating values menu, the value for the length of the tension cylinder is shown in 0 %.

MEGALIFT

STATUS l [%] :

0

α [°] :

F [kN] :

30

(40)

S Y

4-8

Danger of damage to the support cylinder!

When raising, make sure that the end-tensioning posts open properly.

Stop the raising movement immediately if this is not the case, as the endtensioning posts could otherwise bend or break.

• Press up and hold the Raise/lower gantry mast rocker switch until the Gantry mast in 90° position indicator lamp lights up.

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S

0

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Operating manual for Megalift GMK 6300

Operation with main boom and Megalift 4.2 Braced operation

Bringing the main boom into bracing position

H

The crane control allows Megalift tensioning only with certain telescope statuses and respective tensioning angles.

Prior to tensioning the Megalift, the main boom must be brought to a telescope status permitted according to the lifting capacity table and then raised or lowered to the respective tensioning angle.

During retraction of the telescoping, the rope winch of the Megalift automatically follows; telescoping out takes place against the lightly-braked rope winch, so that the guy rope is always held taut.

The main boom can only be telescoped with braced Megalift when – the Megalift control system is switched on – the tension cylinder in the rope winch is locked and – the gantry mast is in 90° position.

à Y

• Check whether the Winch unlocked indicator lamp lights up.

• Check whether the Guy block in 90° position indicator lamp lights up.

• Enter SLI code according to the Lifting capacity table for operation with the Megalift.

• Extend the main boom to the degree that complies with the entered SLI code and lock the telescopic sections.

• On the SLI, press the membrane button Information (2).

The Information display (1) will now indicate the tensioning angle for the current telescoping status (e.g. 20°).

H

If the display shows ==== the main boom is located at a telescoping level that is not permissible for operation with Megalift with the entered SLI code. Bring the main boom to the permissible telescope status.

• Raise or lower the main boom to the indicated tensioning angle.

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The main boom is now in the correct position for tensioning.

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4-9

Operation with main boom and Megalift 4.2 Braced operation

Bracing

The following prerequisites apply to the guy procedure: – The Megalift control system is switched on.

– All telescope sections are locked.

– The gantry mast is in 90° position.

– The appropriate rigging code is set at the SLI. – Apart from the hook block, there is no load on the hoist rope.

– The main boom is now at the tensioning angle Angle shown on the SLI.

X XW W

These conditions are fulfilled when the Bracing released indicator lamp lights up.

• Press down and hold the Automatic bracing rocker switch until the Megalift braced indicator lamp lights up.

If the indicator lamp flashes, this means that the tension cylinder was completely extended in the winch before the necessary pre-tightening force was achieved.

• Check the value for the pre-tightening force at the Crane control display.

MEGALIFT STATUS l [%] :

100

α [°] :

F [kN] :

35

(40)

90

In this case, proceed as follows:

• Restart the guy procedure. To do this, press down and hold the Automatic bracing rocker switch until the Megalift braced indicator lamp lights up.

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V X

• Press down the Unlock winch rocker switch. The winch will be unlocked.

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Operation with main boom and Megalift 4.2 Braced operation

4.2.3

Operation with braced Megalift The fundamental procedures for operation with main boom and braced Megalift are the same as those described for operation with the main boom ➠ GMK 6300 Operating instructions – Working with the crane and main boom.

Telescoping with the Megalift

If you wish to change the telescoping of the main boom during operation with braced Megalift, the following conditions must be met: – The rope winch must be unlocked.

– The main boom must be at an angle specified in the Lifting capacity table.

V

• Press down the Unlock winch rocker switch until the Winch unlocked indicator lamp lights up.

• Raise the main boom to a position acceptable for main boom telescoping.

• Bring the main boom into the telescoping position which is desired and which is given in the Lifting capacity table.

T X Blocked functions

• Press the Wind up winch rocker switch to pretighten the winch again.

• Press down and hold the Automatic bracing rocker switch until the Megalift braced indicator lamp lights up.

When the Megalift is braced, the following functions cannot be carried out as they are blocked by the SLI or the crane control: – Unlocking of telescopic sections – Extending/retracting telescopic sections – Lifting/lowering the gantry mast

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– Winding/unwinding of the winch on the Megalift

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4 - 11

Operation with main boom and Megalift 4.2 Braced operation

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Operating manual for Megalift GMK 6300

Operation with main boom and Megalift 4.3 Axle loads when moving with rigged crane

4.3

Axle loads when moving with rigged crane In this section you will find tables with the axle loads corresponding to the counterweight, boom position, boom angle, telescoping and position of the Megalift. All further information on moving with rigged truck crane; ➠ GMK 6300 Operating instructions – Moving with rigged crane.

G G 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.

Danger of accidents if the truck crane is not completely visible!

While driving the equipped truck crane, always stay in visual or radio contact with a banksman who additionally observes the parts which you cannot see (e.g. the raised boom when the superstructure is turned to the back).

This prevent accidents resulting from collisions with persons, other construction equipment, ledges of buildings, cables or other objects.

Risk of tyre damage!

Check the pressure in the tyres before the rigged truck crane is moved.

The truck crane may be moved only if tyre pressures are at the prescribed levels; ➠ GMK 6300 Operating instructions.

Do not reduce the tyre pressure!

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S

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.

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4 - 13

Operation with main boom and Megalift 4.3 Axle loads when moving with rigged crane

4.3.1

Position of the boom and the Megalift The vehicle may only be moved if certain conditions are met. The boom and the Megalift must be moved to specified positions, depending on the counterweight installed.

S

Damage may occur to the axle lines!

Always move the boom and the Megalift to the prescribed position before you move the rigged truck crane. The permitted load on the axle lines will be exceeded if the boom and the Megalift are in positions which deviate from the prescribed positions.

• Set the appropriate SLI code for the rigging mode on the safe load indicator. The SLI code can be found in the Lifting capacity table.

If the SLI shuts down the lowering of the boom before the boom has reached the prescribed position, you must adjust the current SLI rigging code for the actual rigging mode of the truck crane according to the. Lifting capacity table.

Risk of accidents if SLI is overridden.

Always set the SLI rigging code when you want to lower the partially extended main boom below an angle permitted in the operating area.

Do not override the SLI; if the SLI is overridden, the truck crane works without overload protection.

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H G

• Move the main boom and the Megalift into the prescribed position.

The prescribed boom position is found in the following table.

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Operation with main boom and Megalift 4.3 Axle loads when moving with rigged crane

Axle load tables

Boom positions set down on main boom with Megalift:

Telescoping (Tel. I/II/III/IV)

Boom angle in °

Boom position1)

0 (0)

0/0/0/0

0

front

14.5 (32.0)

12.5 (27.6)

0/0/0/0

82

rear

7.0 (15.4)

16.5 (36.4)

8 (17 637)

0/0/0/0

0

front

12.0 (26.4)

16.0 (35.3)

0/0/0/0

82

rear

9.0 (19.8)

17.5 (38.6)

22 (48 501)

1.0 / 0 / 0 / 0

5

front

22.0 (48.5)

14.5 (32.0)

0/0/0/0

82

rear

12.5 (27.6)

19.5 (43.0)

36 (79 366)

1.0 / 0 / 0 / 0

5

front

17.0 (37.5)

20.5 (45.2)

0/0/0/0

82

rear

16.0 (35.3)

21.0 (46.3)

50 (110 231)

1.0 / 1.0 / 0 / 0

30

front

21.5 (47.4)

22.0 (48.5)

0/0/0/0

82

rear

20.0 (44.1)

23.0 (50.7)

not permissible

–

front

–

–

0/0/0/0

75

rear

27.0 (59.5)

26.5 (58.4)

not permissible

–

front

–

–

not permissible

–

rear

–

–

80 (176 370) 1003) (220 462)

1)

Boom position to the rear = Boom position, front =

2)

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Axle load2) t (x 1000 lbs) front rear

Counterweight in t (lbs)

H

Axle load front: rear:

0° position, boom over rear edge of truck crane 180° position, boom over driver’s cab

on the 1st and 2nd axle lines on the 3rd, 4th and 5th axle lines

The axle loads specified refer to a driving mode with the basic unit including the 35 t (77,160 lbs) hook block.

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4 - 15

Operation with main boom and Megalift 4.3 Axle loads when moving with rigged crane

Boom position rigged for crane operation with Megalift: Axle load2) t (x 1000 lbs) front rear

Counterweight in t (lbs)

Telescoping (Tel. I/II/III/IV)

Boom angle in °

Boom position1)

0 (0)

0/0/0/0

0

front

16.0 (35.3)

12.0 (26.4)

0/0/0/0

82

rear

7.5 (16.5)

16.0 (35.3)

8 (17 637)

0/0/0/0

0

front

13.0 (28.7)

15.5 (34.2)

0/0/0/0

82

rear

9.5 (20.9)

17.0 (37.5)

22 (48 501)

0.5 / 0 / 0 / 0

5

front

15.5 (34.2)

18.0 (39.7)

0/0/0/0

82

rear

13.0 (28.7)

19.0 (41.9)

36 (79 366)

1.0 / 0 / 0 / 0

5

front

20.5 (45.2)

19.0 (41.9)

0/0/0/0

82

rear

17.0 (37.5)

20.5 (45.2)

50 (110 231)

1.0 / 0.5 / 0 / 0

5

front

18.5 (40.8)

23.5 (51.8)

0/0/0/0

82

rear

20.5 (45.2)

22.5 (49.6)

not permissible

–

front

–

–

0/0/0/0

82

rear

28.0 (61.7)

26.0 (57.3)

not permissible

–

front

–

–

not permissible

–

rear

–

–

80 (176 370) 1003) (220 462)

1)

Boom position to the rear = Boom position, front =

2)

4 - 16

on the 1st and 2nd axle lines on the 3rd, 4th and 5th axle lines

The axle loads specified refer to a driving mode with the basic unit including the 35 t (77,160 lbs) hook block.

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H

Axle load front: rear:

0° position, boom over rear edge of truck crane 180° position, boom over driver’s cab

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Operation with main boom and Megalift 4.4 Malfunctions on the Megalift

4.4

Malfunctions on the Megalift

Malfunction

Cause

Remedy

The main boom cannot be telescoped.

Telescoping cylinder is not unlocked.

First unlock the tension cylinder; ➠ Telescoping with Megalift, p. 4-11.

The tension cylinder in the rope winch is not completely retracted (display in menu Megalift operating values).

Completely retract the tension cylinder.

The gantry mast is not in the 90° position (display in menu Megalift operating values).

Bring the gantry mast into the 90° position.

The main boom is at an unsuitable telescoping position.

Bring the main boom into a telescoping position specified in the Lifting capacity table.

The main boom is at the required tensioning angle.

Derrick the main boom to the tensioning angle shown on the SLI

The telescopic sections are not locked.

Lock the telescopic sections

The gantry mast is not in the 90° position (display in menu Megalift operating values).

Bring the gantry mast into the 90° position.

The rigging code on the SLI is not set.

Setting the rigging code on the SLI.

There is a load suspended on the hook block.

Set down the load first.

Rope winch will not turn.

Hydraulic connection at the rope winch is not connected properly.

Establish a hydraulic connection.

The rope winch cannot be wound or unwound.

The tension cylinder in the winch is locked.

Unlock the winch first.

The tension cylinder in the rope winch cannot be locked.

There is a load suspended on the hook block.

Set down the load first.

The proximity switch in the winch is set wrongly.

Set the position of the proximity switch (CraneCARE).

The tractive force on the rope is too large, for the tension cylinder to unlock.

Raise the main boom and unlock again.

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The Megalift cannot be braced.

The tension cylinder in the rope winch cannot be unlocked (Tension cylinder position indicator lamp flashes.

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Operation with main boom and Megalift 4.4 Malfunctions on the Megalift

Malfunction

Cause

Remedy

SLI switches off due to overThe main boom is at an load, although the maximum unsuitable telescoping load allowed has not been ex- position. ceeded.

Bring the main boom into a telescoping position specified in the Lifting capacity table.

No display at the indicator Connecting cable for electrical Establish an electrical and warning lights on the Me- connection at the rope winch connection; galift. loose or not plugged in. ➠ Establishing an electrical connection, p. 3-48.

The Megalift operating values menu is not displayed after the function button has been pressed twice.

Connecting cable for electrical Establish an electrical connection at the rope winch connection; loose or not plugged in. ➠ Establishing an electrical connection, p. 3-48.

The display for the gantry mast angle in the Megalift operating values menu does not change.

Angle sensor is not mechanically connected.

Bring the angle sensor into working position; ➠ p. 3-51.

The gantry mast cannot be raised.

Hydraulic connection is not connected properly.

Establish a hydraulic connection.

There is a load suspended on the hook block.

Set down the load first.

Incline the crane cab back to the horizontal.

Crane cab cannot be inclined.

Gantry mast is too flat.

Raise the gantry mast slightly.

The Megalift braced indicator lamp flashes during automatic bracing.

The tension cylinder is completely extended, but the set tension force was not achieved.

Unlock the tension cylinder and repeat automatic guy procedure.

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The gantry mast cannot be lo- The crane cab is inclined. wered.

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Operation with main boom and Megalift 4.5 Turning loads with the auxiliary single-sheave boom top and Megalift

4.5

Turning loads with the auxiliary single-sheave boom top and Megalift Two-hook operation is required for turning loads. Two-hook operation with the Megalift is also permitted with the auxiliary single-sheave boom top (additional equipment).

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 G H Prerequisites

Risk of accidents due to overloading!

Lifting a load with two hooks is permissible only if the following instructions and illustrations are observed!

If these instructions are not observed, accidents could occur due to individual parts of the truck crane being overloaded! The SLI then no longer provides protection.

Risk of accidents due to overloading!

The load must always be lifted with the weakest part first (auxiliary singlesheave boom top).

For information on the position and function of the operating instruments required; ➠ GMK 6300 Operating instructions – Functional description of the display and operating elements.

The following description requires that: – the Megalift is rigged and braced – the auxiliary single-sheave boom top is installed to the front of the main boom head – the main hoist cable is reeved on the main boom and

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– the auxiliary hoist cable on the auxiliary single-sheave boom top is reeved.

G

Risk of accidents due to overloading!

The reeving on the main boom must be equal to or greater than that on the auxiliary single-sheave boom top.

If this condition is not fulfilled, the main hoist rope and main hoisting gear will become overloaded.

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Operation with main boom and Megalift 4.5 Turning loads with the auxiliary single-sheave boom top and Megalift

Setting SLI

For two-hook operation, both hoists must be activated on the SLI. It is advisable to enter the reevings for both hoists at the start. The values are stored and called up directly when switching hoisting gears. This eliminates the need for input later during operation. Proceed as follows:

Cü ü

• Switch off both hoists.

To do this, press down both rocker switches Auxiliary hoist shutdown and Main hoist shutdown.

• Switch on the main hoist.

To do this, push up the rocker switch Main hoist shutdown.

Lamp I for the main hoist lights up in the Hoists indicator lamps.

• In the display Reeving, enter the quantity of reeved rope of the main hoist rope on the main boom.

Now the reeving for the main hoist is stored and you can switch to the auxiliary hoist.

Cü C

• Switch off both hoists.

To do this, press down both the rocker switch Auxiliary hoist shutdown and the rocker switch Main hoist shutdown.

• Switch on the auxiliary hoist.

To do this, push up the rocker switch Auxiliary hoist shutdown.

At the Hoists indicator lamps, lamp II flashes for the auxiliary hoist.

• In the Reeving display, enter the quantity of reeved rope on the auxiliary hoist rope of the auxiliary single-sheave boom top.

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Now the reeving for the auxiliary hoist is also stored and you can switch on the main hoist.

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Operation with main boom and Megalift 4.5 Turning loads with the auxiliary single-sheave boom top and Megalift

ü

• Switch the main hoist on by pushing up the rocker switch Disconnect auxiliary hoist.

• On the Hoists indicator lamps, lamp II is now lit for the auxiliary hoist and lamp I flashes for the main hoist.

• Set the SLI code for Operation with main boom and Megalift which is valid for the current rigging mode of the truck crane.

H Turning a load

In two-hook operation, the load measurement is taken using 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.

To turn loads, proceed only in the manner described below.

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

Therefore move the load at the lowest possible speed!

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.

With two-hook operation, the SLI code for operation with main boom and Megalift remains activated during the entire hoist procedure.

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S H H

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 with Megalift.

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Operation with main boom and Megalift 4.5 Turning loads with the auxiliary single-sheave boom top and Megalift

• 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.

• 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.

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• Now lift the load with the hook block on the main boom until both slinging points are at the same height.

________________________________________________________________________________________

5

5

Operation with main boom and Megalift

5.1

Untensioned operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

5.1.1 5.1.2

5.2 5.2.1 5.2.2

5- 1 5- 2

Tensioned operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working with tensioned Megalift . . . . . . . . . . . . . . . . . . . . . . . .

5- 3 5- 3

Turning loads with the heavy load lattice extension and Megalift . 5 - 5

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5.3

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working with untensioned Megalift . . . . . . . . . . . . . . . . . . . . . . .

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Operating manual for Megalift GMK 6300

Operation with main boom and Megalift 5.1 Untensioned operation

5

Operation with main boom and Megalift There are two basic operating modes for operation with heavy load lattice extension and Megalift.

Firstly, there is untensioned operation, where the Megalift is rigged on the main boom, but is neither completely erected nor tensioned for operation; ➠ Untensioned operation, p. 4-1.

Secondly, there is tensioned operation, in other words the actual operation with rigged and tensioned Megalift; ➠Tensioned operation, p. 4-7.

5.1

Untensioned operation For operation with heavy load lattice extension and untensioned Megalift, the gantry mast must be raised to 20° with the raising cylinders so that the hoist ropes used, which are guided under the gantry mast, do not become damaged.

5.1.1

Prerequisites • Check whether all the requirements for untensioned operation with the main boom have been met; ➠Prerequisites, p. 4-1.

• Raise the gantry mast to 20°; ➠Raising the gantry mast to 20°, p. 4-2.

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• Lock the winch and break the electrical connection for the Megalift control; ➠Locking the winch and breaking the electrical connection,p. 4-3

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5-1

Operation with main boom and Megalift 5.1 Untensioned operation

5.1.2

Working with untensioned Megalift For operation with the untensioned Megalift, you must set an SLI code for heavy load lattice extension as stated in the Lifting capacity table.

S H

Danger of accidents with improperly rigged truck crane.

The mobile crane may only be operated with untensioned Megalift when the gantry mast is in the 20° position. In all other positions, the hoist ropes would become damaged, or the load distribution on the truck crane would not be secured.

If the Megalift is installed but not tensioned during main boom operation, the values for main boom operation given in the lifting capacity table will be reduced and the SLI will correspondingly switch off earlier.

The reduced values are shown on the SLI displayMaximum Load if you break the electrical connection to the Megalift control only; ➠ Breaking the electrical connection, p. 4-4 The relevant formulas and examples for calculating these values during applications engineering can be found in the Lifting capacity tables.

• On the Hoist gear indicating lamps, switch on the hoist gear whose hoist rope is guided over the heavy load lattice extension. The lamp which lights up must always be for the hoist with which the load is to be lifted.

Lamp I: Lamp II:

for the main hoist gear for the auxiliary hoist.

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All other operations with the heavy load lattice extension (telescopic extensions, derricking etc.) and untensioned Megalift is performed in the same way as described in the chapter Heavy load lattice extension of the GMK 6300 lattice extension operating instructions.

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Operation with main boom and Megalift 5.2 Tensioned operation

5.2

Tensioned operation For heavy load lattice extension operation with tensioned Megalift, the gantry mast must be raised to the 90° position and tensioned in this position.

Before the gantry mast can be tensioned, the main boom must be brought to the respective telescope status and derricked to the respective tensioning angle.

5.2.1

Prerequisites • Check whether all the requirements for tensioned operation with the main boom have been met; ➠ Prerequisites, p. 4-7 The system is tensioned in the way described for main boom operation.

For this purpose, a SLI code for operation with the heavy load lattice extension was entered; ➠ Raising and tensioning the gantry mast, p.4-8.

5.2.2

Working with tensioned Megalift For operation with the tensioned Megalift, you must set an SLI code for heavy load lattice extension as stated in the Lifting capacity table.

• On the Hoist gear indicating lamps, switch on the hoist gear whose hoist rope is guided over the heavy load lattice extension. The lamp which lights up must always be for the hoist with which the load is to be lifted.

Lamp I: Lamp II:

for the main hoist gear, for the auxiliary hoist.

Telescopic extension is performed in the same way as for tensioned main boom operation; ➠ Telescopic extension with Megalift, p. 4-11.

09.08.2005

All other operations with the heavy load lattice extension (telescopic extensions, derricking etc.) and tensioned Megalift is performed in the same way as described in the chapter Heavy load lattice extension of the GMK 6300 lattice extension operating instructions.

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5-3

Operation with main boom and Megalift 5.2 Tensioned operation

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Operation with main boom and Megalift 5.3 Turning loads with the heavy load lattice extension and Megalift

5.3

Turning loads with the heavy load lattice extension and Megalift Two-hook operation is required for turning loads. Two-hook operation with the Megalift is also permitted with the heavy load lattice extension (additional equipment).

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 G H Prerequisites

Danger of accidents due to overloading!

Lifting a load with two hooks is permissible only if the following instructions and illustrations are observed.

If these instructions are disregarded, accidents can occur due to individual parts of the truck crane being overloaded. The SLI then no longer provides protection.

Risk of accidents due to overloading!

The load must always be lifted completely with the weakest part (heavy load lattice extension) first.

For information on the position and function of the operating instruments required; ➠ GMK 6300 Operating instructions - Functional description of the display and operating elements.

The following description requires that: – the Megalift is rigged and tensioned – the heavy load lattice extension is installed in front of the main boom head – the main hoist cable is reeved on the main boom

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– the auxiliary hoist rope on the heavy load lattice extension is reeved

G

Danger of accidents due to overloading!

The reeving on the main boom must be equal to or greater than that on the heavy load lattice extension.

The main hoist cable and main hoisting gear will become overloaded if this condition is not taken into account.

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5-5

Operation with main boom and Megalift 5.3 Turning loads with the heavy load lattice extension and Megalift

H

Setting the SLI

Cü ü

Both hoists must be activated on the SLI for two-hook operation.

It is advisable to enter the reeving values for both hoists right at the start.

The values are stored and called up directly when switching hoists. This eliminates the need for input later on during operation. Proceed as follows:

• Switch off both hoists.

To do this, press down both rocker switches Auxiliary hoist shutdown and Main hoist shutdown.

• Switch on the main hoist.

To do this, push up the Main hoist shutdown rocker switch.

Lamp I for the main hoist lights up in the Hoists indicator lamps.

• In the Reeving display, enter the quantity of reeved ropes of the main hoist rope on the main boom.

Now the reeving for the main hoist has been stored and you can switch to the auxiliary hoist.

Cü C

• Switch off both hoists.

To do this, press down both rocker switches Auxiliary hoist shutdown and Main hoist shutdown.

• Switch on the auxiliary hoist.

To do this, push up the rocker switch Auxiliary hoist shutdown.

At the Hoists indicator lamps, lamp II flashesfor the auxiliary hoist.

Now the reeving for the auxiliary hoist is also stored and you can switch on the main hoist.

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• In the Reeving display, enter the quantity of reeved ropes of the auxiliary hoist rope on the heavy load lattice extension.

Operation with main boom and Megalift 5.3 Turning loads with the heavy load lattice extension and Megalift

ü

• Switch the main hoist on by pushing up the rocker switch Disconnect auxiliary hoist.

• On the Hoists indicator lamps, lamp II is now lit for the auxiliary hoist and lamp I flashes for the main hoist.

• Set the SLI code for Operation with main boom and Megalift which is valid for the current rigging mode of the truck crane.

H Turning a load

In two-hook operation, the load measurement is taken using the pressure in the derricking cylinder. The loads specified in the Lifting capacity table are thus reduced by the weight of both reeved hook blocks and the weight of the heavy load lattice extension.

To turn loads, proceed only in the manner described below.

Keep the acceleration forces as low as possible during two-hook operation.

For this reason, move the load at the lowest possible speed!

The Actual load display shows slight deviations as soon as the hoist rope on the main boom is pulled taut. However, the differences concerning SLI shutdown are on the safe side.

With two-hook operation, the SLI code for operation with main boom and Megalift remains activated during the entire hoist procedure.

09.08.2005

S H H

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 with Megalift.

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5-7

Operation with main boom and Megalift 5.3 Turning loads with the heavy load lattice extension and Megalift

• Lift the load completely off the ground with the heavy load lattice extension.

• Only now should you attach the load to the hook block of the main boom as well.

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

Turning the load has now been completed.

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• Now lift the load with the hook block on the main boom until both slinging points are at the same height.

________________________________________________________________________________________

Alphabetical index

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Alphabetical index

6

Alphabetical index

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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.

From there, you will be referred to more detailed descriptions of these elements.

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Alphabetical index

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Alphabetical index

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Alphabetical index

A

About these operating instructions . . . . . . . . . . . . . . . . 1-1 to 1-2 Additional operating and display elements in the crane cab . . 3-7 to 3-12 function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Axle loads when moving with rigged crane . . . . . . . . . . . 4-13 to 4-16

B

Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . 1-3 to 1-4 organisational measures . . . . . . . . . . . . . . . . . . . . 1-7 to 1-8 proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 to 1-6 qualification of personnel . . . . . . . . . . . . . . . . . . 1-9 to 1-10 safety instructions for work with the truck crane . . . . . . 1-11 to 1-12 warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Blocked functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Boom positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Bracing position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Bridle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

C

CHECKLIST installing the Megalift . . . . . . . . . . . . . . . . . . . . . . . . 3-18 removing the Megalift . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Connection between the rope winch and the main boom . . . . . . . 3-39

E

Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

G

Guide rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

H

Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

I

Identification of the Megalift

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. . . . . . . . . . . . . . . . . . . . . . . . 3-13 to 3-14

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6-3

L

Lock between the gantry mast and the rope winch . . . . . . . . . . . 3-40 Lock between the Megalift and the main boom . . . . . . . . . . . . . 3-36 Lock between the rear pendant links and the gantry mast . . . . . . . 3-44 Lock between the rope winch and the main boom . . . . . . . . . . . 3-35 Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 to 3-62

M

Main boom support for telescopic swing-away lattice extension . . . . . . . . 3-27 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 to 3-60 Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . 3-59 to 3-60 M 3 maintenance plan: every 3 months . . . . . . . . . . . . . . . 3-60 M12 maintenance plan: every 12 months . . . . . . . . . . . . . . 3-60 maintenance plan D: daily . . . . . . . . . . . . . . . . . . . . . . 3-59 maintenance plan W: weekly . . . . . . . . . . . . . . . . . . . . . 3-59 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 to 3-70 condition of the guy rope . . . . . . . . . . . . . . . . . . . . . . 3-65 lubricating the winch gearbox . . . . . . . . . . . . . . . . . . . . 3-69 oil change on the winch gearbox . . . . . . . . . . . . . . . . . . 3-70 oil level in the winch gearbox . . . . . . . . . . . . . . . . . . . . 3-64 position of the rope . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 tightness of the winch gearbox . . . . . . . . . . . . . . . . . . . 3-64 Megalift CHECKLIST: Installing the Megalift . . . . . . . . . . . . . . 3-18, 3-23 components . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 to 3-14 identification . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 to 3-14 lashing eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 pre-tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 to 3-6

O

Operation with heavy load lattice extension and Megalift tensioned operation . . . . . . . . . . . . . . . . . . . . . . 5-3 to 5-4 untensioned operation . . . . . . . . . . . . . . . . . . . . . 5-1 to 5-2 working with tensioned Megalift . . . . . . . . . . . . . . . . . . . 5-3 Operation with main boom and Megalift . . . . . . . 4-1 to 4-23, 5-1 to 5-9 braced operation . . . . . . . . . . . . . . . . . . . . . . . 4-7 to 4-12 non-braced operation . . . . . . . . . . . . . . . . . . . . . . 4-1 to 4-6 operation with braced Megalift . . . . . . . . . . . . . . . . . . . 4-11 operation with non-braced Megalift . . . . . . . . . . . . . . . . . . 4-5 working with untensioned Megalift . . . . . . . . . . . . . . . . . . 5-2

P

Plastic supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

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Alphabetical index

Alphabetical index

Raising the gantry mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 Raising the gantry mast . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 to 3-58 Rope guide on the main boom . . . . . . . . . . . . . . . . . . . . . . 3-54

S

Setting down the gantry mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Supplementary instructions to the GMK 6300 operating instructions crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 rope grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

T

Telescoping with the Megalift . . . . . . . . . . . . . . . . . . . . . . 4-11 Transport dimensions and weights in metric units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 in US units . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 to 2-3 Turning loads with auxiliary single-sheave boom top and Megalift . . . . 4-19 to 4-23 with heavy load lattice extension and Megalift . . . . . . . . 5-5 to 5-9 Two-hook operation . . . . . . . . . . . . . . . . . . 4-19 to 4-23, 5-5 to 5-9

W

Working position/transport position of the angle sensor . . . . . . . . 3-51 Working position/transport position of the raising cylinder . . . . . . 3-47

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Operating manual for Megalift GMK 6300

09.08.2005