Auxiliary single-sheave boom top1

9.1 Operations planning 9.1.1 Identification

GRisk of accidents if auxiliary single-sheave boom tops are interchanged! Install only a auxiliary single-sheave boom top that belongs to the truck crane. No other auxiliary single-sheave boom tops may be installed.

The truck crane and the corresponding auxiliary single-sheave boom top must be labelled with the same serial number (1).

9.1.2 Slinging points

GRisk of accidents if used improperly! Only fit slings to the auxiliary single-sheave boom top at the slinging points provided. Use only lifting gear and joining elements of sufficient load bearing capacity.

The fixed slinging point (1) is marked with a sticker (2).

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

A guide rope (4) is fastened to the rope guide.

9.1.3 Transport dimensions and weights

9.1.4 Transport condition

SRisk of damage to the auxiliary single-sheave boom top!

Always secure the auxiliary single-sheave boom top by tying it down with suitable belts when it is being transported on a separate vehicle. This prevents the auxiliary single-sheave boom top tipping over and becoming damaged during transportation.

GRisk of injury if the pins are not secured!

Before transport make sure that all pins are secured in the clamps with retaining pins. Secure any pins that are not secure. This way you prevent the pins from falling down while driving and injuring or even killing other persons.

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9.2 Description of the rigging

9.2 Description of the rigging work

9.2.1 Moving the auxiliary single-sheave boom top into the operating position

GRisk of accidents due to swinging parts!

Always secure the sections with a guide rope from the ground before establishing or separating connections.

This prevents you from being crushed or caught by swinging sections.

After transport on a separate vehicle

• (A) – Attach the auxiliary single-sheave boom top to an auxiliary crane; à p.9-2.

• Align the connecting points (2).

• (B) – Take the pins (1) out of the clamp (3) and insert them into the connecting points(2).

• Secure the pins.

• Remove the lifting gear.

After transport on the main boom

• Fold the locking bar (1) upwards.

• Secure the locking bar.

Securing the strut

• Take the strut (2) from the clamps (3).

• Insert the retaining pins into the clamps (3).

• Remove the pin (5).

• Insert the strut (2) with the peg (4) into the connecting point (1).

• Secure the strut with the pin (5) and the retaining pin.

Swinging the auxiliary single-sheave boom top round and locking it

• Swing the auxiliary single-sheave boom top so that the connecting point (3) is aligned with the strut (2).

• Remove the pin (4) from the clamp (1) and plug it into the connecting point (3).

• Secure the pin.

9.2 Description of the rigging

9.2.2 Moving the auxiliary single-sheave boom top into the transport position

GRisk of accidents due to swinging parts!

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

Removing the strut

• Remove the pin (2) from the connecting point (3) and plug it into the clamp (1).

• Secure the pin.

• Remove the strut (7) from the connecting point (4).

• Secure the pin (5) to the strut (7).

• Plug the strut (7) onto the clamp (6).

• Secure the strut.

For transportation on a separate vehicle

• Sling the auxiliary single-sheave boom top to an auxiliary crane; à p.9-2.

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

• Secure the pins.

• Lift the auxiliary single-sheave boom top from the head of the main boom.

Auxiliary single-sheave boom top1

9.2 Description of the rigging work

For transport on the main boom

• Swing the auxiliary single-sheave boom top on to the main boom.

• Fold the locking bar (1) down so that it engages in the clamp (2).

• Secure the locking bar.

9.2 Description of the rigging

9.2.3 Installing/removing a folded up auxiliary single-sheave boomtop

GRisk of accidents due to swinging parts!

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

Installing

• Sling the auxiliary single-sheave boom top to an auxiliary crane; à p.9-2.

• Align the connecting points (2).

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

• Secure the pins.

• Swing the auxiliary single-sheave boom top on to the main boom.

• Fold the locking bar (4) down so that it engages in the clamp (5).

• Secure the locking bar.

• Remove the lifting gear.

Removing

• Sling the auxiliary single-sheave boom top to an auxiliary crane; à p.9-2.

• Fold the locking bar (4) upwards.

• Secure the locking bar.

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

• Secure the pins.

• Lift the auxiliary single-sheave boom top from the main boom.

9.2.4 Attaching/removing the hoist rope

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

Fitting

• Remove the rods (3) and (5).

• Move the rod (4).

–Remove the retaining pins from the rod (4).

–Move the rod (4) in the direction of the arrow so that it is not over the sheave (1).

–Secure the rod (4).

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

• Insert the rods (3) and (5).

• Secure the rods.

Removing

• Remove the rods (3) and (5).

• Remove the hoist rope from the sheaves (1) and (2).

• Insert the rods (3) and (5).

• Secure the rods.

• Move the rod (4).

–Remove the retaining pins from the rod (4).

–Move the rod (4) in the direction of the arrow so that it is over the sheave (1).

–Secure the rod (4).

9.2 Description of the rigging work

Possible reeving methods

1 sheave hook block and hook tackle

Reeving

A 1x

Auxiliary single-sheave boom top1

9.2 Description of the rigging work

9.2.5 Installing / removing the lifting limit switch and anemometer

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

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

Installation

–After separate transport

• Insert the lifting limit switch into the clamp (5) and secure it.

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

–After transport on the auxiliary singlesheave boom top

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

• Lay the cable (4) so that it will not be damaged during crane operation.

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

Removing

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

• Take the plug (2) out of the socket (1) and close the socket with the cap.

–For separate transport

• Remove the lifting limit switch (5).

–For transport on the auxiliary single-sheave boom top

• Insert the plug (2) into the dummy socket(3).

• Wind the cable (4) on to the clamps (6).

9.2 Description of the rigging work

AnemometerInstalling and removing

You must install the anemometer for operation with the auxiliary singlesheave boom top.

For transportation you must take off the anemometer.

Installation and removal are performed in the same way as for operation with the main boom; à GMK5150 / GMK5150L Operating Instructions

GRisk of damage during transport!

Before transport, remove the anemometer. This prevents the anemometer being damaged by sudden air currents.

Auxiliary single-sheave boom top1 9.2 Description of the rigging work

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Auxiliary single-sheave boom top1

9.3 Operation with the auxiliary single-sheave boom top1

9.3 Operation with the auxiliary single-sheave boom top1

The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will need for a rigged or folded up auxiliary single-sheave boom top.

9.3.1 Setting the RCL

Input

• Input the current rigging mode for operation with the main boom into theRCL.

• Input the current reeving at the auxiliary single-sheave boom top into the RCL for the hoist whose hoist rope is reeved to the auxiliary single-sheave boom top.

Shutdown Operation with the auxiliary single-sheave boom top is monitored by the RCL. When operating with the auxiliary single-sheave boom top, RCL shutdowns may occur for the same reasons as when operating with the main boom; à GMK5150 / GMK5150L Operating Instructions

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

–During operation with the auxiliary single-sheave boom top

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

–The weight of the lifted load (2) and

–The weight of the hook block (3) and

–The weight of the auxiliary single-sheave boom top (4).

Auxiliary single-sheave boom top1

9.3 Operation with the auxiliary single-sheave boom top1

–During main boom operation

If an auxiliary single-sheave boom top (4) is installed, then the displayed current load (1) is influenced by

–The weight of the lifted load (2) and

–The weight of the hook block (3) and

–The weight of the auxiliary single-sheave boom top (4).

9.3.2 Procedure if permissible wind speeds are exceeded

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

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

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

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

• Immediately cease crane operation.

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

9.3.3 Instructions for turning loads over

à Turning loads over, p.11-1.

9.4 Maintenance

HIf the auxiliary single-sheave boom top has been in storage for an extended period of time, perform maintenance work on it no later than when it is next used.

9.4.1

Maintenance work on the AUXILIARY SINGLE-SHEAVE BOOM TOP: Monthly/after approx. 100 operating hours

Auxiliary single-sheave boom top

M 1

–Lubricate the pins à p.9-18

9.4.2

Maintenance work on the AUXILIARY SINGLE-SHEAVE BOOM TOP: every three months/after 250 oper. hrs.

Auxiliary single-sheave boom top

M 3

–Check the sheaves à p.9-18

9.4.3 Description of maintenance work

Grease 1) Designation to DIN 51502

1) à Maintenance manual

Lubricate the pins

• Grease the pins (1) and the pegs (3).

Check the sheaves

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

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