Grove Crane GMK 5200 GMK 6220 GMK 6220 L Lattice Extension Operating Instructions Manual 3112208

Operating instructions lattice extension

Vehicle serial number:

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Important note

Duplications of any kind and excerpts from this document are not subject to the alterations service. Original documents of Deutsche GROVE GmbH are marked with the blue serial number of the truck crane on the cover page.

© Copyright reserved by Deutsche GROVE GmbH Weitergabe und Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten zum Schadensersatz. Alle Rechte für den Fall der Patenteintragung und Gebrauchsmustereintragung vorbehalten.

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Operating instructions lattice extension GMK 5200/6220/6220-L

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

The following chapters are contained in these operating instructions: a

1 Important information 2 Dimensions and weights 3 Two-stage swing-away lattice extension 4 Boom extension 5 Auxiliary single-sheave boom top 6 Heavy load lattice extension

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7 Alphabetical Index

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1 Important information

1.1

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

1

1.2

Fundamental safety instructions for crane operators . . . . . . . . . . . . . . . . . . . . . . 1 -

2

1.2.1

Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

2

1.3

Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

3

1.4

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

5

1.5

Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

7

1.6

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

8

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Operating instructions lattice extension GMK 5200/6220/6220-L

Important information 1.1 About these operating instructions

1

Important information

1.1

About these operating instructions

H Validity of this operating manual

All the lattice extensions described in these operating instructions can be obtained as additional equipment.

These operating instructions apply exclusively to the telescopic swing-away lattice extension supplied by the Deutsche GROVE GmbH. For operating the truck crane with the telescopic swing-away lattice extension, all the specifications in the supplied Operating instructions of the GMK 5200/6220/6220-L, which the telescopic swing-away lattice extension was supplied for by the works, also apply.

Prerequisites for assembly and operation

The telescopic swing-away lattice extension may only be operated together with the GROVE mobile crane GMK 5200/6220/6220-L, whose serial number is identical with that of the telescopic swing-away lattice extension.

General safety instructions

When operating the GMK 5200/6220/6220-L with the telescopic swing-away lattice extension, the crane operator needs to observe: – the general safety instructions in the following section Fundamental safety instructions for crane operators and – the safety instructions listed in the supplied operating instructions of the GMK 5200/6220/6220-L.

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Reference to other operating instructions

Cross references to other operating or maintenance instructions are shown in the following forms: Example: operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Setting rigging mode.

The number for the chapter on Rigging work is found in front on the third page of the operating instructions indicated. or operating instructions for the truck crane – Safe load indicator The page where safe load indication is described can be found in the index.

à

à

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1-1

Important information 1.2 Fundamental safety instructions for crane operators

1.2

Fundamental safety instructions for crane operators

1.2.1

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

H s 1-2

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

This symbol alerts you to situations where you are in danger of receiving an electric shock.

This symbol is to remind you that you are working with substances which pose a risk to the environment. Take particular care. Further information about handling substances which are harmful to the environment; Maintenance manual, chapter Safety and environmental protection.

à

The vertical line to the left of the text indicates: This text regardless of its length belongs 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.

So turn to the next page!

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G S B O

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

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Important information 1.3 Proper use

1.3

Proper use The GMK 5200/6220/6220-L truck crane is constructed in accordance with the state of the art and the recognised 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 5200/6220/6220-L 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.

Without the corresponding special equipment, the truck crane GMK 5200/ 6220/6220-L may only be operated at an ambient temperature of –25 to +40 °C. The GMK 5200/6220/6220-L truck crane is to be used exclusively for the 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 considered improper.

The manufacturer is not liable for damage resulting from the improper or unauthorised use of the GMK 5200/6220/6220-L 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, – following the inspection and maintenance requirements specified in the maintenance manual.

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1-3

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 at the main boom head without additional equipment, – operation when crane is not on outriggers (free on wheels), – defining SLI codes that do not correspond to the actual rigging mode, – working with an overridden SLI or overridden lifting limit switch, – after SLI deactivation, the radius must be increased by pulling the 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 override (outrigger pressure greater than 0 t), – road driving in an unauthorised driving mode (axle load, dimension), – transporting hoisted loads by moving the truck crane, – moving the rigged crane in an unauthorised driving mode, – using equipment that is not authorised for use with the crane, – transporting people in any way with the lifting tackle, on the load and in the crane cab during driving, – carrying passengers outside the driver’s cab, – loading and unloading work, i.e. continuous operation without a corresponding break,

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– usage for any kind of sport or recreation event, especially for “bungee jumping”.

1-4

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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 and should not be removed from the truck crane. You need to have read and understood the operation and safety instructions in these operating instructions and to 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 need to have read and understood these and to work accordingly.

This includes: – the use of hazardous materials, – wearing protective clothing and equipment, – traffic regulations or – all regulations aplying to the ooertion of the 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 instruction.

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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1-5

Important information 1.4 Organisational measures

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

Familiarise 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 is 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 – installing safety devices, – adjusting safety devices and valves.

Welding work on load-bearing parts may only be conducted by properly qualified personnel following authorisation by the manufacturer. To avoid any damage, especially to electronic parts, there are certain steps you must take before doing any welding work. So always consult CraneCARE 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 in the prescribed intervals or have them replaced, even if no safety defects are noticeable.

Replacement parts must fulfil 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.

1-6

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Important information 1.5 Personnel qualifications

1.5

Personnel qualifications These operating instructions are not a training manual for prospective crane operators!

All descriptions are written explicitly for crane operators who have been trained to operate truck cranes.

Employees in training may only operate the truck crane under strict supervision.

Only reliable personnel may operate the truck crane.

As a truck crane operator you are obliged to fulfil 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 titled You as crane driver and operator in the Safety manual.

Only experienced personnel familiar with the applicable accident prevention regulations are authorised 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 offers general and model-related courses for crane operators and crane technology.

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1-7

Important information 1.6 Safety instructions for truck crane work

1.6

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

Walk around the truck crane before beginning crane work. Check the 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.

Before commencing work with the crane, check daily that all covers and safety devices are correctly fitted and in an acceptable condition.

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

When doing rigging or maintenance work above head height, use the intended climbing aids. Do not use machine parts as limbing aids.

Step 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 walking, use the extendable ladder which accompanies the machine (e.g. when reeving the hoist cable on the boom nose).

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 label them as such.

When lifting a load, raise the boom to balance out the increase in radius caused by the boom bending so that the load is lifted up when in a vertical position and does not drag, injure helpers or fall into the hoist rope diagonally (e.g. from a vehicle or scaffold). Inform banksmen and helpers about this as well.

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

1-8

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

Important information 1.6 Safety instructions for truck 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.

Always put down the load before you stop work.

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

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Crane work carried out in the vicinity of supply lines such as oil, gas and power 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 note the relevant national regulations.

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1-9

Important information 1.6 Safety instructions for truck crane work

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Blank Page

1 - 10

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2 Dimensions and weights

2.1

Dimensions and weights in metric units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1

2.1.1 2.1.2 2.1.3 2.1.4

Two-stage swing-away lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1 1 1 2

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2

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Dimensions and weights 2.1 Dimensions and weights in metric units

2

Dimensions and weights

2.1

Dimensions and weights in metric units This section contains information on the transportation measurements and weights of lattice extensions in metric units.

2.1.1

2.1.2

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2.1.3

Two-stage swing-away lattice extension

Description

Length x width x height (m)

Weight (kg)

12.5 m part, complete

13.0 x 1.00 x 1.50

1850

9 m part, complete

9.10 x 0.55 x 0.75

550

Two-stage swing-away lattice extension, complete, folded

13.0 x 1.15 x 1.50

2400

Hose drum, complete with hoses

1.30 x 1.30 x 0.35

160

Auxiliary single-sheave boom top

Description

Length x width x height (m)

Weight (kg)

Auxiliary single-sheave boom top

1.05 x 0.95 x 1.00

60

Description

Length x width x height (m)

Weight (kg)

8 m part, complete, each

8.20 x 0.90 x 1.15

790

Boom extension

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2-1

Dimensions and weights 2.1 Dimensions and weights in metric units

Heavy load lattice extension

Description

Length x width x height (m)

Weight (kg)

Heavy load lattice extension 2 m

1.88 x 1.05 x 1.10

341

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2.1.4

2-2

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3 3

Two-stage swing-away lattice extension

3.1

Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

1

3.1.1 3.1.2

Operating elements in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operating elements on two-stage swing-away lattice extension . . . . . . . . . . . 3 -

1 3

3.2

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

5

3.3

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

7

3.4

Slinging points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

9

3.5

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11

3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7

Overview of the required rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11 CHECK LIST: Installing two-stage swing-away lattice extension. . . . . . . . . . . . 3 - 12 CHECK LIST: Removing two-stage swing-away lattice extension . . . . . . . . . . . 3 - 14 CHECK LIST: Rigging 13 m swing-away lattice extension . . . . . . . . . . . . . . . . . 3 - 16 CHECK LIST: Unrigging 13 m swing-away lattice extension . . . . . . . . . . . . . . . 3 - 20 CHECK LIST: Rigging 22 m two-stage swing-away lattice extension . . . . . . . . 3 - 24 CHECK LIST: Unrigging 22 m two-stage swing-away lattice extension . . . . . . 3 - 28

3.6

Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33

3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.6.7 3.6.8 3.6.9 3.6.10 3.6.11 3.6.12 3.6.13 3.6.14 3.6.15 3.6.16 3.6.17 3.6.18

Preparing the truck crane for rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33 Checking the transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35 Hose drum for hydraulic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 38 Connections with folded-up lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 43 Pin connections to swing the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 48 Pin connections for working with the lattice extension . . . . . . . . . . . . . . . . . . . 3 - 52 Lowering/raising retaining mandrel on main boom . . . . . . . . . . . . . . . . . . . . . . 3 - 57 Swinging the lattice extension when rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 61 Run-up rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 63 Swinging the lattice extension onto the main boom head . . . . . . . . . . . . . . . . 3 - 64 Electrical connection on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 65 Establishing/disconnecting the hydraulic connection . . . . . . . . . . . . . . . . . . . . 3 - 67 Folding out/in the deflection sheaves on the 12.5 m section . . . . . . . . . . . . . . . 3 - 68 Positioning hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 70 Lifting limit switch on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 72 Anemometer on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 74 Derricking lattice extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 75 Transportation on a separate vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 76

3.7

Raising the setting down the main boom with rigged lattice extension . . . . . . 3 - 77

3.7.1 3.7.2

Telescoping with rigged lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 78 Operation with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 78

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3.8

Turning loads with the two-stage swing-away lattice extension . . . . . . . . . . . . 3 - 81

3.8.1 3.8.2

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 81 Setting SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 82

3.9

Driving with rigged crane and two-stage swing-away lattice extension installed

3 - 87

Driving route. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rigging mode and axle loads GMK 5200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rigging mode and axle loads GMK 6220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rigging mode and axle loads GMK 6220-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

87 88 91 94 98

3.10

Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 101

3.10.1 3.10.2

Two-stage swing-away lattice extension malfunctions . . . . . . . . . . . . . . . . . . . 3 - 101 Malfunctions on the SLI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 102

3.11

Maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 105

3.11.1

Maintenance plan M 1: monthly / after 100 Oh . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 105

3.12

Table of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 107

3.13

Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 109

3.13.1

Modules in need of protection during cleaning work. . . . . . . . . . . . . . . . . . . . . 3 - 109

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3.9.1 3.9.2 3.9.3 3.9.4 3.9.5

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Two-stage swing-away lattice extension 3.1 Operating and display elements

3

Two-stage swing-away lattice extension

H 3.1

The correct designation “two-stage swing-away lattice extension” is in this chapter substituted with the designation “lattice extension” in order to improve readability.

Operating and display elements If the GMK 5200/6220/6220-L is rigged with a two-stage swing-away lattice extension, certain operating and display elements in the crane cab are also applicable to operating the lattice extension.

This section describes all operating and display elements required for the operation of the lattice extension.

Furthermore, this chapter describes the operating elements located directly on the lattice extension.

3.1.1

Operating elements in the crane cab

Operating elements on the instrument panel

_

Rocker switch for preselection of control lever function derricking/telescoping/derricking lattice extension Switches the control lever function between derricking gear, telescoping gear and lattice extension.

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Derricking lattice extension control lever function:

Press rocker switch down

Ü

Rocker switch for switching off derricking gear/derricking lattice extension

Z

Indicator lamp for right-hand control lever in derricking function

To switch off the functions Derricking and Derricking lattice extension to prevent unintentional activation.

Illuminates when the control lever function Derricking has been selected.

Operating instructions lattice extension GMK 5200/6220/6220-L

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3-1

Two-stage swing-away lattice extension 3.1 Operating and display elements

Righthand control lever Raise lattice extension:

Control lever to the left

Lower lattice extension:

Control lever to the right

Operating elements of the SLI Lattice extension length display and input 1 Display:

Lattice extension length in metres (m) or feet (ft) – for displayed SLI code

2 Input:

In input mode button once – next length Press

R

Lattice extension angle display and input The manual inclinable lattice extension is connected.

1 Display:

Angle between lattice extension and main boom in degrees (°) – for displayed SLI code

2 Input:

In input mode button once – next angle Press

T

– Displaying current overall height Overall height = vertical distance between the lower edge of the outrigger pad and the highest point of the main boom or lattice extension.

After pressing the button (1), the lamp (2) lights up, and the current overall height is shown. The value displayed depends on whether meters (m) or feet (ft) have been set.

The displayed value is valid for fully extended outrigger cylinders on the largest outrigger span.

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The lamp (3) is not used.

3-2

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.1 Operating and display elements

3.1.2

Operating elements on two-stage swing-away lattice extension

Switch unit

1

Raise lattice extension push-button

2

Lower lattice extension push-button

à p. 3 - 75 à p. 3 - 75

Functional description Raise lattice extension push-button (additional equipment) To raise the lattice extension when rigging.

The lattice extension is raised when the push-button is pressed or until the end position or a switch-off point is reached.

Lower lattice extension push-button (additional equipment)

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To lower the boom the lattice extension when rigging.

The lattice extension is lowered when the push-button is pressed or until the end position or a switch-off point is reached.

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3-3

Two-stage swing-away lattice extension 3.1 Operating and display elements

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.2 Identification

3.2

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

The following parts are identified by the serial number: – the 12.5 m section on the fixed section, – the 12.5 m section on the luffing section, – the 9 m section.

S H

S

Operate only two-stage swing-away lattice extension sections which have the same serial number as the crane.

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

This prevents malfunctions and damage.

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

If you wish to use the two-stage swing-away lattice extension on several GROVE truck cranes, the two-stage swing-away lattice extension sections must be adjusted for the corresponding cranes and labelled with all of the respective serial numbers.

The two-stage swing-away lattice extension should only be adjusted by CraneCARE!

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3-5

Two-stage swing-away lattice extension 3.2 Identification

Serial numbers on 12.5 m section

The 12.5 m section consists of a fixed section and a luffing section.

On the luffing section you will find the serial number (1) at the top, on the sheet in front of the deflection sheave.

The serial number (2) is at the bottom of the sheet on the foot of the fixed section.

Serial number on 9 m section

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On the 9 m section the serial number (1) is on the retaining sheet for the pins.

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.3 Assembly

3.3

Assembly

13 m swing-away lattice extension 0.5 m foot section

12.5 m part

22 m two-stage swing-away lattice extension 0.5 m foot section

12.5 m part

The 12.5 m section consists of a fixed 2 m section and a 10.5 m luffing section.

The 0.5 m foot section serves as a connection between the main boom head and the lattice extension. It is an integral part of the lattice extension.

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H

9 mpart

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3-7

Two-stage swing-away lattice extension 3.3 Assembly

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.4 Slinging points

3.4

Slinging points

G

Danger of accidents if the lifting gear is incorrectly slung!

The slinging points for the different rigging modes of the two-stage swingaway lattice extension can be seen in the following drawing. Sling the sections to these slinging points only, as they then automatically have the correct centre of gravity. Only use sling gear with sufficient load bearing capacity; Weight of individual parts p. 2 - 1.

à

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On the 12.5 m section there are five slinging points (welded-on rope holders). The following diagram shows which slinging points you must use for particular rigging modes.

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Two-stage swing-away lattice extension 3.4 Slinging points

Slinging points for the 12.5 msection alone

• Sling the 12.5 m section alone onto the two slinging points (4) and (5) so that it is in the centre of gravity.

• Guide the sling rope from outside around the struts onto the slinging points to prevent tipping to the side.

Slinging points for 22 m two-stage swingaway lattice extension, 9 msection folded at the side

• Sling the folded 22 mtwo-stage swing-away lattice extension only onto the two slinging points (3) and (5) so that it is in the centre of gravity.

• Guide the rope at point (5) from inside and at point (3) from outside around the strut of the 12.5 m section onto the slinging points to prevent tipping to the side.

Slinging points for 22 m two-stage swingaway lattice extension, 9 m section swungout

• Sling the rigged 22 m two-stage swingaway lattice extension only onto the two slinging points (1) and (2) so that it is in the centre of gravity.

• Guide the sling rope from outside around

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the struts onto the slinging points to prevent tipping to the side.

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

3.5

Checklists for rigging work

3.5.1

Overview of the required rigging work There are different initial states for rigging the lattice extension, depending on whether – the lattice extension is folded at the side of the main boom or – the lattice extension has been removed for on-road driving with a maximum axle load of 12 t; operating instructions for the truck crane, Part 1, Chapter Driving with the truck crane, Section Checking the truck crane before driving – Driving mode table.

à

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

Before crane operation

Initial state

Corresponding rigging work

lattice extension is on the side of the main boom

CHECKLISTS: Rigging 13 m swing-away latp. 3 - 16. tice extension; Rigging 22 m two-stage swingaway lattice extension; p. 3 - 24.

à

à

After crane operation

lattice extension was removed completely

CHECKLIST: Installing two-stage swingaway lattice extension; à p. 3 - 12.

lattice extension should be folded at the side of the main boom

CHECKLISTS: Unrigging 13 m swing-away p. 3 - 20. lattice extension; Unrigging 22 m two-stage swing-away lattice extension; p. 3 - 28.

à

à

lattice extension should be removed for on-road driving

CHECKLIST: Removing two-stage swingaway lattice extension; p. 3 - 14.

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à

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3 - 11

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

3.5.2

CHECK LIST: Installing two-stage swing-away lattice extension

H

This checklist is not equivalent to complete operating instructions. There are accompanying instructions which are indicated by cross-references.

Observe the warning and safety information given there!

Prerequisites for 5200 / 6220-L: – The truck crane is on outriggers or The main boom is set down on the boom rest.

– The main boom is fully retracted.

– An auxiliary crane is available.

Prerequisites for 6220: – The truck crane is supported on outriggers.

– The superstructure must be turned to the rear or to the side.

– The main boom is fully retracted.

– An auxiliary crane is available.

1. Install and connect hose drum for hydraulic supply (if applicable); Installing hose drum, p. 3 - 39.

à

2. Check the transport condition of the two-stage swing-away lattice Transport condition with removed lattice extension, p. 3 - 37. extension;

à

3. Sling two-stage swing-away lattice extension on auxiliary crane; Slinging points, p. 3 - 9.

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à

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

4. Lift two-stage swing-away lattice extension with auxiliary crane in front of the main boom and create a swinging connection between the 12.5 m section and the main boom; Connections on main boom head, p. 3 - 48.

à

5. Establish hydraulic connection between lattice extension and main Establishing/disconnecting the hydraulic connection, p. 3 - 67. boom;

à

6. Establish electrical connection between lattice extension and main 13 m swing-away lattice extension, p. 3 - 65. boom;

à

H

If the lattice extension needs to be rigged in front of the main boom, see Point 9.

7. If the lattice extension needs to be folded at the side of the main boom, move run-up rail into Unrigging position; Run-up rail, p. 3 - 63.

à

8. The other types of rigging work are described in the CHECK LIST: Unrigging 13 mswing-away lattice extension from Point 14, p. 3 - 22.

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3 - 13

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

9. If the lattice extension needs to be rigged in front of the main boom, attach guide ropes to the head of the 12.5 m section.

The other types of rigging work for the 13 m swing-away lattice extension are described in the CHECK LIST: Rigging 13 m swing-away lattice extension from Point 15, p. 3 - 18.

The other types of rigging work for the 22 m two-stage swing-away lattice extension are described in the CHECK LIST: Rigging 22 m twostage swing-away lattice extension from Point 12, p. 3 - 25.

3.5.3

CHECK LIST: Removing two-stage swing-away lattice extension

H

This checklist is not equivalent to complete operating instructions. There are accompanying instructions which are indicated by cross-references.

Observe the warning and safety information given there!

Prerequisites for 5200 / 6220-L: – The truck crane is on outriggers or The main boom is set down on the boom rest.

– The main boom is fully retracted.

– An auxiliary crane is available.

Prerequisites for 6220: – The truck crane is supported on outriggers.

– The superstructure must be turned to the rear or to the side.

– The main boom is fully retracted.

– An auxiliary crane is available.

1. Carry out all of the rigging work for a rigged 13 m swing-away lattice extension listed in the CHECK LIST: Unrigging 13 m swing-away lattice exp. 3 - 20. tension up to and including Point 12;

2. Carry out all of the rigging work for a rigged 22 m two-stage swingaway lattice extension listed in the CHECK LIST: Removing 22 m two-stage swing-away lattice extension up to and including point 18, p. 3 - 28.

à

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à

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

3. Disconnect hydraulic connection between lattice extension and main boom; Establishing/disconnecting the hydraulic connection, p. 3 - 67.

à

4. Disconnect electrical connection between lattice extension and main 13 m swing-away lattice extension, p. 3 - 65. boom;

à

5. Sling two-stage swing-away lattice extension on auxiliary crane; Slinging points, p. 3 - 9.

à

6. Loosen swinging connection between 12.5 m section and basic section and set down two-stage swing-away lattice extension onto separate vehicle with auxiliary crane; Connections on main boom head, p. 3 - 48.

Transportation on a separate vehicle, p. 3 - 76.

à à

à Installing

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7. Remove hose drum for hydraulic supply (if applicable); hose drum, p. 3 - 39.

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3 - 15

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

3.5.4

CHECK LIST: Rigging 13 m swing-away lattice extension

H

This checklist is not equivalent to complete operating instructions. There are accompanying instructions which are indicated by cross-references.

Observe the warning and safety information given there!

1. Prepare the truck crane for rigging the swing-away lattice extension; Preparing the truck crane for rigging, p. 3 - 33.

à

2. Install/connect hose drum for the hydraulic supply of the lattice extension (if applicable); Installing hose drum, p. 3 - 39.

à

3. Check that the lattice extension was unrigged properly and is in transTransport condition with lattice extension folded at the siport condition; de, p. 3 - 37.

à

4.Move run-up rail into rigging position;

H

à Run-up rail, p. 3 - 63.

When only the 12.5 m section is folded at the side of the main boom: see Point 8.

5. Establish connection between 9 m section and main boom in front area; Connection between 9 m section and main boom, p. 3 - 45.

à

6. Remove the connection between the 9 m and 12.5 m sections; Connections in the front area, p. 3 - 44.

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à

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

7. Remove the connection on the pivot point between the 12.5 m and 9 m sections; Connections on lattice extension, p. 3 - 50.

à

8. If only the 12.5 msection is folded at the side of the main boom, remove connection between 12.5 m section and run-up rail; à Connections in the middle area, p. 3 - 46.

9. Establish hydraulic connection between lattice extension and main Establishing/disconnecting the hydraulic connection, p. 3 - 67. boom;

à

10. Establish electrical connection between lattice extension and main boom; 13 m swing-away lattice extension, p. 3 - 65.

à

11. Swing 12.5 m section onto the main boom head; extension onto the main boom head, p. 3 - 64.

à Swinging the lattice

12. Establish the swinging connection between the 12.5 m section and the Connections on main boom head, p. 3 - 48. main boom head;

à

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3 - 17

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

13. Secure the 12.5 m section with guide rope on the main boom; Securing lattice extension with cord, p. 3 - 59.

à

14. Lower lattice extension with retaining mandrel out of the holder on the Lowering/raising retaining mandrel on main boom, p. 3 - 57. main boom;

à

15. Swing 12.5 m section in front of the main boom head; lattice extension when rigging, p. 3 - 61.

à Swinging the

16. Lock 12.5 m section on the left side of the main boom and, if required, lower the lattice extension to the ground to relieve the load on the bearing points; Connections on the main boom head, p. 3 - 53.

Relieving the load on bearing points, p. 3 - 53.

à à

17. Lock 12.5 m section on the right side of the main boom; on the main boom head, p. 3 - 53.

à Folding out/

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18. Fold out both deflection sheaves on the 12.5 m section; in the deflection sheaves on the 12.5 m section, p. 3 - 68.

à Connections

3 - 18

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

19. Place hoist rope above both deflection sheaves and the head sheave on the 12.5 m section; Positioning hoist rope, p. 3 - 70.

à

20. Move anemometer (additional equipment) from the head of the main Anemometer on the lattice exboom to the head of the 12.5 m section; tension, p. 3 - 74.

à

21. Move lifting limit switch from the head of the main boom to the head of Lifting limit switch on the lattice extension, p. 3 - 72. the 12.5 m section;

à

à

operating instructions for the 22. Reeve the hoist rope on the hook block; truck crane, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope.

23. Attach lifting limit switch weight and guiding hoist rope through the operating instructions for the truck crane, Part 2, Chapter Rigweight; ging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope – lifting limit switch weight.

à

24. Enter the SLI code according to the Lifting capacity table for the actual rigging mode of the truck crane with the 13 m swing-away lattice extension; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Operation of the safe load indicator – Setting the rigging mode.

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à

à p. 3 - 77. à p. 3 - 78.

Further working steps for raising the boom; Telescoping with rigged lattice extension;

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3 - 19

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

3.5.5

CHECK LIST: Unrigging 13 m swing-away lattice extension

H

This checklist is not equivalent to complete operating instructions. There are accompanying instructions which are indicated by cross-references.

Observe the warning and safety information given there!

1. Prepare the truck crane for unrigging; ging, p. 3 - 33.

à Preparing the truck crane for rig-

2. Fully retract and set down boom.

For GMK 6220: Turn the main boom to the rear or to the side.

3. Enter the SLI code according to the Lifting capacity table for the actual rigging mode of the truck crane with the 13 m swing-away lattice extension; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Operation of the safe load indicator – Setting the rigging mode.

à

4. Remove lifting limit switch weight and moving lifting limit switch from the head of the 12.5 m section to the head of the main boom; Lifting limit switch on the lattice extension, p. 3 - 72.

à

5. Unreeve the hoist rope from the hook block and roll it onto a drum; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope.

à

à Anemometer on the lat-

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6. Remove anemometer (additional equipment); tice extension, p. 3 - 74.

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

7. Lower lattice extension until it is on the ground with the supports on the head of the 12.5 m section, remove hoist rope from head sheave and deflection sheaves and place on the left side of the lattice extension on the ground.

8. Fold in both deflection sheaves; the 12.5 m section, p. 3 - 68.

à Folding out/in the deflection sheaves on

9. Reel up hoist rope up to the main boom head.

10. Move run-up rail into the Unrigging position;

à Run-up rail, p. 3 - 63.

11. Remove locking pin between 12.5 m section and main boom head on the left side of the main boom; Connections on the main boom head, p. 3 - 53.

Relieving the load on bearing points, p. 3 - 53.

à à

12. Remove locking pin between 12.5 m section and main boom head on the right side of the main boom; Connections on the main boom head, p. 3 - 53.

à

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3 - 21

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

13. Attach the guide rope to the head of the 12.5 m section and raise the lattice extension completely.

14. Swing 12.5 m section onto the main boom; sion when rigging, p. 3 - 61.

à Swinging the lattice exten-

15. Raise lattice extension with retaining mandrel in the holder on the main Lowering/raising retaining mandrel on main boom, p. 3 - 57. boom;

à

16. Remove the swinging connection between the 12.5 m section and the Connections on main boom head, p. 3 - 48. main boom head;

à

17. Swing the 12.5 m section on the run-up rail onto the main boom; Swinging the lattice extension onto the main boom head, p. 3 - 64.

à

H

If the 9 m section is not attached to the main boom proceed as from Point 20.

18. Establish connection on the pivot point between the 12.5 m and 9 m Connections on lattice extension, p. 3 - 50. sections;

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à

3 - 22

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

19. Establish connection between 9 m and 12.5 m sections; Connection between 9 m section and main boom, p. 3 - 45.

à

20. If the 9 m section is not attached to the main boom, lock the 12.5 m secConnections in the middle area, p. 3 - 46. tion on the run-up rail;

à

21. Disconnect hydraulic connection between lattice extension and main Establishing/disconnecting the hydraulic connection, p. 3 - 67. boom;

à

22. Disconnect electrical connection between lattice extension and main 13 m swing-away lattice extension, p. 3 - 65. boom;

à

23. Check whether the lattice extension is in transport position; Checking the transport condition, p. 3 - 35.

à

à Installing

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24. Remove hose drum for hydraulic supply (if applicable); hose drum, p. 3 - 39.

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3 - 23

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

3.5.6

CHECK LIST: Rigging 22 m two-stage swing-away lattice extension

H

This checklist is not equivalent to complete operating instructions. There are accompanying instructions which are indicated by cross-references.

Observe the warning and safety information given there!

1. Prepare the truck crane for rigging the swing-away lattice extension; Preparing the truck crane for rigging, p. 3 - 33.

à

2. Install/connect hose drum for the hydraulic supply of the lattice extension (if applicable); Installing hose drum, p. 3 - 39.

à

3. Check that the lattice extension was unrigged properly and is in transTransport condition with lattice extension folded at the siport condition; de, p. 3 - 37.

à

4. Move run-up rail into rigging position;

à Run-up rail, p. 3 - 63.

5. Disconnect connection between 9 m section and main boom; Connections in the rear area, p. 3 - 47.

à

6. Establish hydraulic connection between lattice extension and main Establishing/disconnecting the hydraulic connection, p. 3 - 67. boom;

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à

3 - 24

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

7. Establish electrical connection between lattice extension and main boom; 13 m swing-away lattice extension, p. 3 - 65.

à

8. Swing 12.5 m section onto the main boom head; extension onto the main boom head, p. 3 - 64.

à Swinging the lattice

9. Establish the swinging connection between the 12.5 m section and the main boom head; Connections on main boom head, p. 3 - 48.

à

10. Secure the 12.5 m section with guide rope on the main boom; Securing lattice extension with cord, p. 3 - 59.

à

11. Lower lattice extension with retaining mandrel out of the holder on the Lowering/raising retaining mandrel on main boom, p. 3 - 57. main boom;

à

12. Swing two-stage swing-away lattice extension in front of the main Swinging the lattice extension when rigging, p. 3 - 61. boom head;

à

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

13. Lock 12.5 m section on the left side of the main boom and, if required, lower the lattice extension to the ground to relieve the load on the bearing points; Connections on the main boom head, p. 3 - 53.

Relieving the load on bearing points, p. 3 - 53.

à à

14. Lock 12.5 m section on the right side of the main boom; on the main boom head, p. 3 - 53.

à Connections

15. Attach guide rope to the head of the 9 m section and remove connection between 9 m (30 ft) and 12.5 m (41 ft) sections; Connection between 9 m section and main boom, p. 3 - 45.

à

16. Raise lattice extension fully and swing the 9 m section in front of the Swinging the 9 m section in front of the 12.5 m sec12.5 m (41 ft) section; tion, p. 3 - 62.

à

17. Lock the 9 m (30 ft) section in front of the 12.5 m section; Connections on lattice extension, p. 3 - 55.

Relieving the load on bearing points, p. 3 - 53.

à à

18. Establish the electrical connection between the 12.5 m and 9 m sec22 m two-stage swing-away lattice extension, p. 3 - 66. tions;

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à

3 - 26

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

19. Fold out both deflection sheaves on the 12.5 m section and the 9 m (30 ft) section; Folding out/in the deflection sheaves on the 12.5 m section, p. 3 - 68.

à

20. Place hoist rope on the 9 m section via all deflection sheaves and the Positioning hoist rope, p. 3 - 70. head sheave;

à

21. Move anemometer (additional equipment) from the head of the main Anemometer on the lattice extenboom to the head of the 9 m section; sion, p. 3 - 74.

à

22. Move lifting limit switch from the head of the main boom to the head of Lifting limit switch on the lattice extension, p. 3 - 72. the 9 m section;

à

à

operating instructions for the 23. Reeve the hoist rope on the hook block; truck crane, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope.

24. Attach lifting limit switch weight and guide hoist rope through the operating instructions for the truck crane, Part 2, Chapter Rigweight; ging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope – lifting limit switch weight.

à

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

25. Enter SLI code according to the Lifting capacity table for the actual rigging mode of the truck crane with the 22 m two-stage swing-away lattice extension; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Operation of the safe load indicator – Setting the rigging mode.

à

à p. 3 - 77. à p. 3 - 78.

Further working steps for raising the boom; Telescoping with rigged lattice extension;

3.5.7

CHECK LIST: Unrigging 22 m two-stage swing-away lattice extension

H

This checklist is not equivalent to complete operating instructions. There are accompanying instructions which are indicated by cross-references.

Observe the warning and safety information given there!

1. Prepare the truck crane for unrigging; ging, p. 3 - 33.

à Preparing the truck crane for rig-

2. Fully retract and set down main boom.

For GMK 6220: Turn the main boom to the rear or to the side.

3. Enter the SLI code according to the Lifting capacity table for the actual rigging mode of the truck crane with the 22 m two-stage swing-away lattice extension; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Operation of the safe load indicator – Setting the rigging mode.

à

4. Remove lifting limit switch weight and move lifting limit switch from the head of the 9 m section to the head of the main boom; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope – lifting limit switch weight.

à

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à

5. Unreeve the hoist rope from the hook block; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope.

Two-stage swing-away lattice extension 3.5 Checklists for rigging work

6. Remove anemometer (additional equipment); tice extension, p. 3 - 74.

à Anemometer on the lat-

7. Lower lattice extension until it is on the ground with the supports on the head of the 9 m section, remove hoist rope from head sheave and deflection sheaves and place on the left side of the lattice extension on the ground.

8. Disconnect the electrical connection between the 9 m and 12.5 m sec22 m two-stage swing-away lattice extension, p. 3 - 66. tions;

à

9. Fold in both deflection sheaves; the 12.5 m section, p. 3 - 68.

à Folding out/in the deflection sheaves on

10. Reel up hoist rope up to the main boom head.

H

If the 9 m section needs to be removed and only the 12.5 m section at the side of the main boom needs to be folded, see Point 15.

11. Attach the guide rope to the 9 m section of the lattice extension.

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

12. Remove locking pins between 9 m section and 12.5 m section on the left side and remove the lower pin on the right side with the head (left 2 pins, right 1 pin); Connections on lattice extension, p. 3 - 55.

Relieving the load on bearing points, p. 3 - 53.

à à

13. Raise lattice extension and swing 9 m section at the side onto the 12.5 m (41 ft) section; Swinging the 9 m section in front of the 12.5 m section, p. 3 - 62.

à

14. Establish connection between 9 m and 12.5 m sections; in the middle area, p. 3 - 46.

à Connections

15. If the 9 m section needs to be removed, attach 9 m section on auxiliary crane, remove all locking pins between 9 m (30 ft) section and 12.5 m section and place 9 m section on separate vehicle.

16. Move run-up rail into the Unrigging position;

à Run-up rail, p. 3 - 63.

17. Lower lattice extension until it is on the ground with the supports on the head of the 12.5 m section and remove the locking pin between the 12.5 m section and the main boom head on the left side of the main boom; Connections on the main boom head, p. 3 - 53.

Relieving the load on bearing points, p. 3 - 53.

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à à

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

18. Remove locking pin between 12.5 m section and main boom head on the right side of the main boom; Connections on the main boom head, p. 3 - 53.

à

19. Attach the guide rope to the head of the 12.5 m section and raise the lattice extension completely.

20. Swinging 12.5 m section onto the main boom; tension when rigging, p. 3 - 61.

à Swinging the lattice ex-

21. Raise lattice extension with retaining mandrel in the holder on the main Lowering/raising retaining mandrel on main boom, p. 3 - 57. boom;

à

22. Remove the swinging connection between the 12.5 m section and the Connections on main boom head, p. 3 - 48. main boom head;

à

23. Swing the 12.5 m section on the run-up rail onto the main boom; Swinging the lattice extension onto the main boom head, p. 3 - 64.

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à

H

If the 9 m section has been removed, see Point 25.

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Two-stage swing-away lattice extension 3.5 Checklists for rigging work

24. Establish connection between 9 m section and main boom; Connections in the rear area, p. 3 - 47.

à

25. If the 9 m section has been removed, lock the 12.5 m section on the runConnections in the middle area, p. 3 - 46 up rail;

à

26. Disconnect hydraulic connection between lattice extension and main Establishing/disconnecting the hydraulic connection, p. 3 - 67. boom;

à

27. Disconnect electrical connection between 12.5 m section and main 13 m swing-away lattice extension, p. 3 - 65. boom;

à

28. Check whether the lattice extension is in transport position; Checking the transport condition, p. 3 - 35.

à

à Installing

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29. Remove hose drum for hydraulic supply (if applicable); hose drum, p. 3 - 39.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6

Description of rigging work

3.6.1

Preparing the truck crane for rigging

Requirements for rigging

Before you rig a two-stage swing-away lattice extension, the following requirements must be met: – The two-stage swing-away lattice extension is attached to the side of the main boom and is in transport condition.

– The counterweight version required acc. to the Lifting capacity table for the planned operation when the lattice extension is rigged.

– The truck crane is supported with the prescribed outrigger span for the planned operation with the lattice extension according to the Lifting capacity table and is aligned horizontally.

– If the truck crane is equipped with two hoists with additional equipment, the hook block is unreeved on the hoist which is not used for working with the lattice extension. for GMK 5200 / 6220-L: – The main boom is fully retracted (0/0/0/0/0) and lowered to the horizontal. for GMK 6220: Before telescoping, – the superstructure must be turned to the side or to the rear – the lattice extension must be fully raised so that the bearing points between the main boom and the lattice extension align.

S

Risk of damage when setting down on the boom rest When the main boom is set down in the boom rest fully retracted or in such a way that the bearing points do not align, the driver's cab and the lattice extension could be damaged.

Therefore, slew the superstructure to the side or to the rear.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Requirements for unrigging

If the following prerequisites are met, the boom with the lattice extension may be lowered into the horizontal; Raising the setting down the main boom with rigged lattice extension, p. 3 - 77.

à

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

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

– The double swing-away lattice extension is fully raised.

– The SLI code for operation with rigged double swing-away lattice extension has been entered. additional instructions for GMK 6220: The superstructure must be turned to the rear or to the side.

S

Risk of damage when setting down on the boom rest When the main boom is set down in the boom rest fully retracted or in such a way that the bearing points do not align, the driver's cab and the lattice extension could be damaged.

Therefore, slew the superstructure to the side or to the rear.

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

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.2

Checking the transport condition For transportation you must establish certain connections between both parts of the lattice extension. The connections which need to be established depend on whether the lattice extension: – is folded up at the side of the main boom for transportation or – is completely removed for transportation.

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

S

Be careful not to damage the lattice extension and the main boom!

Always put the lattice extension into transport condition before driving the truck crane with a lattice extension folded at the side or working with the main boom.

Only then is the lattice extension secured against slipping.

In this way you prevent the partly fastened lattice extension hitting the main boom or the individual components of the lattice extension hitting each other and becoming damaged.

You must check transport condition: – After unrigging the lattice extension, before you drive the truck crane with the lattice extension folded at the side or work with the main boom.

– Before installation and before rigging the lattice extension.

The corresponding checklists require that the lattice extension is in transport condition.

The following paragraphs and the diagram show the necessary connections for the transport condition with the lattice extension folded at the side and removed.

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3 - 35

Two-stage swing-away lattice extension 3.6 Description of rigging work

B

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8

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Transport condition with lattice extension folded at the side

The transport condition with the lattice extension folded at the side is created when all of the following connections are established.

• Check the connections and establish them if necessary.

If the 9 m section and 12.5 m section are folded at the side: – The 12.5 m section is raised into the holder on the main boom with the Lowering/raising retaining mandrel on main boom, retaining mandrel (1); p. 3 - 57.

à

– The 12.5 m section is secured with the locking pin (8); 12.5 m section, p. 3 - 58.

à Locking pin for

– The connection is made (2) between the 9 m section and the 12.5 m section; Connections in the front area, p. 3 - 44.

à

– The connections (3) and (4) are made on the pivot point between the 9 m Connections on lattice extension, p. 3 - 50. section and the 12.5 m section;

à

If only the 12.5 m section is folded at the side: – The 12.5 m section is raised into the holder on the main boom with the Lowering/raising retaining mandrel on main boom, retaining mandrel (1); p. 3 - 57.

– The 12.5 m section is secured with the locking pin (8); Locking pin for 12.5 m section, p. 3 - 58.

– The connection (6) is made between the 12.5 m section and the run-up rail; à Connections in the middle area, p. 3 - 46.

à

à

If only the 9 m section is folded at the side: – The connection (5) is made between the 9 m section and the main boom; Connections in the rear area, p. 3 - 47.

à

– The connection (7) is made between the 9 m section and the main boom; Connections in the front area, p. 3 - 44.

à

Transport condition with removed lattice extension

The transport condition for the removed lattice extension is created when all of the following connections are established.

• Check the connections and establish them if necessary.

– The connections (3) and (4) are made on the pivot point between the 9 m Connections on lattice extension, p. 3 - 50. section and the 12.5 m section;

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à

– The connection (4) is made between the 9 m section and the 12.5 m secConnections in the front area, p. 3 - 44. tion;

à

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.3

Hose drum for hydraulic supply The hydraulic supply for the lattice extension is via a hose drum on the lefthand side of the main boom.

Depending on the driving mode of the truck crane the hose drum must be removed for on-road driving with a maximum axle load of 12 t; operating instructions for the truck crane, Part 1, Chapter Driving with the truck crane, Section Checking the truck crane before driving – Driving mode table.

à

When working with the main boom for longer the hydraulic connection between the hose drum and the main boom head should be disconnected.

This prevents the unnecessary reeling and unreeling of the hose.

The following rigging processes are described in this section: – Locking device for transportation; p. 3 - 38.

à Locking device for transportation,

à Installing hose drum, p. 3 - 39.

– Removal of the hose drum; à Removing hose drum, p. 3 - 40.

– Installation of the hose drum;

– Establishing and disconnecting the connection between the hose drum Hydraulic connection, p. 3 - 40. and the main boom head;

à

Locking device for transportation

The hose drum is equipped with a locking device. The locking device prevents the hose drum twisting unchecked against the holder when releasing the strain relief because of initial tension.

You must always insert the locking device before releasing the strain relief (1) from the holder (2) on the main boom.

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You may release the anti-twist device only after you have attached the strain relief (1) back in the holder (2) on the main boom.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

S

Risk of accidents from unchecked turning hose drum!

You may release the anti-twist device only when you have attached the strain relief on the main boom beforehand.

By doing this you prevent the hose drum twisting unchecked against the holder and the turning hydraulic hoses injuring other people.

There are eight bores (1) above the radius on the inner flanged wheel (2) of the hose drum.

Inserting anti-twist device

• Turn the hose drum until a bore is in front of the spring latch (3).

• Move the spring latch into the bore, the hose drum is secured against twisting.

Removing anti-twist device

• Attach the strain relief on the main boom before removing.

• Withdraw spring latch (3) from the bore in the flanged wheel.

Installing hose drum

If the hose drum has been removed for on-road driving, you must re-install it before working with the lattice extension.

• Attach the hose drum to the recesses (1) with an auxiliary crane.

• Lift the hose drum onto the left side of the main boom.

• First move the upper threaded pins (6) diagonally from below into the retaining sheets (5).

• Then swing the hose drum down onto the main boom so that the lower threaded pins (3) slide into the retaining sheet (2).

• Insert the spacer sheets (4).

• Attach the hose drum by turning the nuts on the threaded pins (3) and (6).

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3 - 39

Two-stage swing-away lattice extension 3.6 Description of rigging work

Removing hose drum

Before removing the hose drum the hydraulic connection to the hose drum must be disconnected.

• Insert the locking device; à Locking device for transportation, p. 3 - 38.

• Attach the hose drum to the recesses (1) with an auxiliary crane.

• Unscrew the nuts from the threaded pins (3) and (6).

• Remove the spacer sheets (4).

• Swing the hose drum down from the main boom so that the threaded pins (3) slide out of the retaining sheet (2).

• Lower the hose drum until the upper threaded pins (6) are no longer in the bores of the retaining sheet (5).

• Lift the hose drum off the main boom and place it on a separate vehicle.

Hydraulic connection

Risk of accidents from hydraulic hoses springing back!

If you release the strain relief after the locking device has been released, you must not let go of the strain relief until it is attached again.

If you let go of the strain relief, the hydraulic hoses will spring back because of the spring force in the hose drum and may injure people or damage parts of the truck crane.

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G

After installing the hose drum the hydraulic connections need to be made.

Before removing or before working with the main boom for a long time you must disconnect the hydraulic connection.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Establishing hydraulic connection The hose drum is connected hydraulically on the main boom basic section and the main boom head.

H

The connections are made via quick-action couplings.

Half couplings belonging together are colour coded.

Use the delivered levering tool to make the hydraulic connections; Connecting quick couplings with levering tool, p. 4 - 18.

à

• Remove the protective caps and connect the hydraulic hoses with the quick-action couplings (2) to the half couplings (1).

• Remove the strain relief from the holder (1) on the main boom and pull the hydraulic hoses (2) to the main boom head.

• Attach the strain relief on the holder (3).

• Guide the hydraulic hoses through the guide rollers (5).

• Connect the hydraulic hoses with the quickaction couplings (4) to the half couplings on the main boom head (observe colour code).

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Disconnecting hydraulic connection If you want to remove the hose drum, you must disconnect the hydraulic connections on the main boom head and on the main boom basic section.

If the hose drum is still installed, you only need to disconnect the connections on the main boom head.

• Remove the quick-action couplings from the connections (4) on the main boom head and put the protective caps in place.

• Move the hydraulic hoses out of the guide rollers (5).

• Release the strain relief on the holder (3), move the hoses back to the hose drum and attach the strain relief on the holder (1).

• When working with the main boom, hang the hydraulic hoses through the holder (2) on the main boom; if the hose drum needs to be removed, you must insert the locking device; p. 3 - 38.

à

If the hose drum needs to be removed, you must also disconnect the connections on the main boom basic section.

• Remove the quick-action couplings (2) from the half couplings (1) on the main boom basic section.

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• Put the protective caps in place.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.4

Connections with folded-up lattice extension In the folded position the lattice extension is swung at the side of the main boom.

In this position there are three areas where, during rigging and unrigging, different connections must be disconnected and then re-established: – in the rear area (1), in front of the crane engine – in the middle area (2), on the run-up rail – in the front area (3), in front of the pivot point of the derricking cylinder In all the areas you will find one or two bearing points on which connections can be made. Depending on the rigging mode and the type of job, different parts of the lattice extension must be connected together or with the main boom basic section.

G

Risk of accidents from falling parts!

Always secure the pins both in the bearing points and in the holders with retaining pins.

This prevents unsecured pins coming loose, falling and injuring people.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Connections in the front area Connection between 9 m section and 12.5 m section The connection must be made: – or transportation, – for installation and removal, – when unrigging the 22 m two-stage swing-away lattice extension.

The connection must be disconnected: – when rigging the 13 m swing-away lattice extension, – when rigging the 22 m two-stage swing-away lattice extension.

Disconnecting connection

• Swing the catch hook (3) out of the bracket (1) into position A.

• When rigging the 13 m swing-away lattice extension, swing the 12.5 m section in front of the main boom. Then swing the catch hook back to the attachment point (4) in position B.

• When rigging the 22 m two-stage swingaway lattice extension, swing the 9 m section away from the 12.5 m section a little and then move the catch hook back to the attachment point (4) in position B. Making connection

• Check if the catch hook is in position B. • When unrigging the 13 m swing-away lattice extension, swing the 12.5 m section gently onto the 9 m section – the catch hook (3) latches behind the bracket (1).

• When unrigging the 22 m two-stage swing-

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away lattice extension, swing the 9 m section gently onto the 12.5 m section – the catch hook (3) latches behind the bracket (1).

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Connection between 9 m section and main boom The connection must be made: – When rigging the 13 m swing-away lattice extension, – for transportation when only the 9 m section is folded at the side of the main boom.

The connection must be disconnected: – When rigging the 22 m two-stage swing-away lattice extension, – after operation with 13 m swing-away lattice extension when the lattice extension needs to be removed.

Making connection

• Swing the 9 m section fully onto the main boom.

• Attach the 9 m section to the main boom with the pin (1).

• Secure the pin with the retaining pin.

Disconnecting connection

• Remove the pin (1) from the connection and insert it in the bore (2).

• Secure the pin with the retaining pin.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Connections in the middle area In the middle area, on the run-up rail, there is a bearing point between the 12.5 m section and the main boom.

The connection must be made when only the 12.5 m section is folded at the side of the main boom.

The connection must be disconnected when the lattice extension needs to be rigged again from this state.

Making connection

• Swing the 12.5 msection on the run-up rail fully onto the main boom.

• Remove the pin (1) from the holder (2) and attach the 12.5 m section to the main boom with the pin.

• Secure the pin with the retaining pin.

Disconnecting connection

• Remove the pin (1) from the connection and insert it in the holder (2).

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• Secure the pin with the retaining pin.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Connections in the rear area In the rear area, on the main boom, there is a bearing point between the 9 m section and the main boom.

The connection must be made: – when unrigging the 22 mtwo-stage swing-away lattice extension, – for operation with the 13 m swing-away lattice extension.

The connection must be disconnected: – when rigging the 22 m two-stage swing-away lattice extension, – for removing the 22 mtwo-stage swing-away lattice extension.

Disconnecting connection

• Swing the lever (1) on one of the two handles (2) away from the main boom until you hear the spring latch (3) engage.

The spring latch holds the lever in this position and the connection is disconnected.

Making connection

• Swing the lattice extension fully onto the main boom.

• Turn the spring latch (3) downwards as far as it will go.

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The lever (1) clicks back in the direction of the main boom and the connection is made.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.5

Pin connections to swing the lattice extension Before you can swing the lattice extension when rigging in front of the main boom head or when unrigging on the basic section, you must make or disconnect different connections, depending on the rigged lattice extension.

To swing the 13 m swing-away lattice extension you must make connections on the main boom head.

To swing the 22 m two-stage swing-away lattice extension you must also make connections on the pivot point between the 12.5 m section and the 9 m section of the two-stage swing-away lattice extension.

The connections on the bearing points are made with pins. The pins are inserted into holders on the lattice extension and are secured with retaining pins.

G

Risk of accidents from falling parts!

Always secure the pins both in the bearing points and in the holders with retaining pins.

This prevents unsecured pins coming loose, falling and injuring people.

Connections on main boom head

When rigging the 13 m (43 ft) swing-away lattice extension and the 22 m two-stage swing-away lattice extension, the foot section of the 12.5 m section is always locked on the right side of the main boom head with two pins.

3 - 48

à

If the pins can not be inserted fully or get stuck, retract the main boom against the stop.

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H H

Before you can lock the foot section of the lattice extension on the main boom head, the lattice extension must be swung onto the main boom head; Swinging the lattice extension onto the main boom head, p. 3 - 64.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Establishing connection between 12.5 m section and main boom head The connection must be made: – for swinging the 13 m swing-away lattice extension, – for swinging the 22 m two-stage swing-away lattice extension.

• Release the retaining pins and remove the two pins from the holders (3) and (4).

• Insert one pin into each of the bearing points (1) and (2).

• Secure both pins with the retaining pins.

Disconnecting connection between 12.5 m section and main boom head The connection must be disconnected so that the lattice extension can be swung at the side of the main boom.

H

Before you disconnect this connection, the lattice extension must be raised into the bearing point on the main boom; Lowering/raising retaining mandrel on main boom, p. 3 - 57.

à

• Remove the retaining pins and pull the two pins (1) and (2) out of bearing points (1) and (2).

• Insert a pin into each of the holdings (3) and (4).

• Secure both pins with the retaining pins.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Connections on lattice extension

The two parts of the lattice extension are connected at the pivot point of the two-stage swing-away lattice extension.

The connection must be made: – for transportation, – for installation and removal, – when unrigging the 13 m swing-away lattice extension, – when rigging the 22 m two-stage swing-away lattice extension.

The connection must be disconnected: – for rigging the 13 mswing-away lattice extension, – when only the 12.5 m section needs to be folded on the side of the main boom for transportation.

G

Risk of accidents from the 12.5 m section slipping!

If you have disconnected the connection when rigging the 13 m swingaway lattice extension, make sure you re-establish the connection during unrigging. Only then is the 12.5 m section secured against slipping.

This prevents the 12.5 m section slipping or falling off during transportation or main boom operation.

Making connection

• Remove the retaining pin, take the swivel pin out of the holder (3) and insert it in the bearing point (2) for swinging.

• Remove the retaining pin, take a securing pin out of the retaining sheet (4) and insert it in the bearing point (1) for swinging and operation.

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• Secure both pins with retaining pins.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Disconnecting connection

• Remove the retaining pins and take both pins out of the bearing points (1) and (2).

• Insert the swivel pin in the holder (3) and the securing pin in the retaining sheet (4).

• Secure the two pins using retaining pins.

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G

Risk of accidents from the 12.5 m section slipping!

If you have disconnected the connection when rigging the 13 m (43 ft) swing-away lattice extension, make sure you re-establish the connection during unrigging. Only then is the 12.5 m section secured against slipping.

This prevents the 12.5 m section slipping or falling off during transportation or main boom operation.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.6

Pin connections for working with the lattice extension If you have swung the lattice extension in front of the main boom head when rigging or before you are able to swing it onto the main boom during unrigging you must make or disconnect different connections, depending on the rigged lattice extension.

If you have swung the 13 m swing-away lattice extension in front of the main boom head, you must make all connections on the main boom head or, when unrigging, disconnect them.

If you have swung the 22 m two-stage swing-away lattice extension in front of the main boom head, you must also make connections on the two-stage swing-away lattice extension or, when unrigging, disconnect them.

The connections are made with pins on the bearing points.

The pins are inserted in holders on the lattice extension and are secured with retaining pins.

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G

Risk of accidents due to falling parts!

Always secure the pins both in the bearing points and in the holders using retaining pins. This prevents unlocked pins from becoming loose, falling out and causing injuries.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Relieving the load on bearing points

The dead weight of the lattice extension can lead to the bearing points on the left side not being aligned or the pins becoming under load and not being able to be knocked out.

This affects the connections between the main boom head and the 12.5 m section or between the 12.5 m section and the 9 m section.

When making or disconnecting the connections proceed as follows:

• Override the lifting limit switch and lower the lattice extension until it is on the ground with the supports (1).

• Continue to lower until the bearing points (2) align or until the load has been removed from the pins; Derricking lattice extension, p. 3 - 75.

à

Connections on the main boom head

If the bearing points for locking do not align or the pins can not be knocked out, the load must be removed from the bearing points; p. 3 - 53.

If the 13 m swing-away lattice extension or the 22 m two-stage swing-away lattice extension is swung in front of the main boom head, the foot section of the 12.5 m section is locked on both sides of the main boom head with two pins on both sides.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Locking 12.5 m section in front of the main boom head The securing pins for this connection are in the holders (1) on the foot of the 12.5 m section and are secured with retaining pins.

• First insert the two pins (3) and (6) on the right side into the bearing points.

• Then insert the two other pins (2) and (7) into the bearing points on the left side (if necessary derrick the lattice extension to align the bearing points).

• Secure all the pins with retaining pins.

H

The swivel pins (4) and (5) remain inserted for working with the lattice extension.

Removing locking pins between 12.5 m section and main boom head

• First release the pins on the left side and then knock them out of the bearing points (2) and (7) (if necessary derrick the lattice extension to relieve the load on the pins).

• Then release the pins (3) and (6) on the right side and knock them out of the bearing points.

• Insert all pins in the holders (1) and secure the pins with retaining pins.

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H

Insert the swivel pins (4) and (5) into the bearing points.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Connections on lattice extension

If the bearing points for locking do not align or the pins can not be knocked out, the load must be removed from the bearing points; p. 3 - 53.

If the 9 m section is swung in front of the 12.5 m section when rigging the 22 m two-stage swing-away lattice extension, it must be locked on the head of the 12.5 m section.

The securing pins for this connection are all in the retaining sheet (1) on the foot of the 9 m section and are secured with retaining pins.

A securing pin (2) has already been inserted for the swinging connection.

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3 - 55

Two-stage swing-away lattice extension 3.6 Description of rigging work

Locking 9 m section and 12.5 m section

• First insert the securing pin (3) into the bottom bearing point on the right side.

• Then insert the two securing pins (1) and (2) into the bearing points on the left side (if necessary derrick the lattice extension to align the bearing points).

• Secure all the pins with retaining pins.

H

The swivel pin (4) remains inserted for work with the lattice extension.

Removing locking pins between 9 m section and 12.5 m section on the left side

• Remove the retaining pins and then knock the two pins out of the bearing points (1) and (2) on the left side (if necessary derrick the lattice extension to relieve the load on the pins).

• Then remove the retaining pins and knock the securing pin out of the lower bearing point (2) on the right side.

• Insert all three pins in the keeper plate (1) and secure them with retaining pins.

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H

Insert the swivel pin (3) and the upper securing pin (4) in the bearing points.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.7

Lowering/raising retaining mandrel on main boom If the lattice extension is folded on the side of the main boom, the retaining mandrel is inserted on the 12.5 m section in a holder on the main boom.

This connection is both a swinging point for swinging the lattice extension on the run-up rail and a safety device.

Requirements

Before you lower the retaining mandrel, – the swinging connection must be made between the 12.5 m section and the main boom head; p. 3 - 48.

à

– the lattice extension must be secured against swinging around with a Securing lattice extension with cord, p. 3 - 59. cord on the main boom;

à

– the locking pin for the 12.5 m section must be inserted in the released position; Locking pin for 12.5 m section, p. 3 - 58.

à

Before you raise the retaining mandrel – the lattice extension must be fully lowered; – the lattice extension must be fully folded on the main boom.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Locking pin for 12.5 m section

The 12.5 m section is secured with a locking pin on the basic section so that during work with the main boom or when driving the retaining mandrel can not slip upwards out of the holder.

The locking pin (2) is at the front of the basic section where the 12.5 m section is. There are two locking pin positions: Secured position

• Insert the locking pin (2) in one of the bores (4) so that it is above the stop connection piece (3). Secure the pin with a retaining pin.

In this position the 12.5 m section is secured so that it can not slip out upwards.

Released position

• Insert the locking pin (2) in the bore (1) and

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secure it with a retaining pin.

Now the 12.5 m (section can be raised for rigging.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Securing lattice extension with cord

If the truck crane is aligned unfavourably the lattice extension may swing round by itself after lowering out of the holder on the main boom.

Secure the lattice extension as follows:

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

• Guide the cord underneath the lattice extension, via the holding rod (1) on the main boom and back again.

• Have a helper hold the cord tight whilst you are lowering the lattice extension out of the holder on the main boom.

H Lowering/raising the retaining mandrel

G

If you are alone, secure the other end of the cord on the crane (e.g. on the steps of the access ladder leading to the carrier). Leave enough play in the cord that it is tight only when you swing the lattice extension from the runup rail later.

The lattice extension can be derricked from two control units on the lattice extension during rigging; p. 3 - 75.

à

Accidents may occur due to swinging lattice extension!

Always secure the lattice extension against unintentional swinging with a cord before you lower the retaining mandrel out of the holder.

This prevents the lattice extension swinging by itself away from the main boom and hitting you from the truck crane if there is an unfavourable alignment of the truck crane.

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3 - 59

Two-stage swing-away lattice extension 3.6 Description of rigging work

Lowering

• Insert the locking pin for the 12.5 m section in position Released;

à p. 3 - 58.

• Lower the lattice extension until the retaining mandrel (2) is fully out of the holder (1) on the main boom.

Raising

• Raise the lattice extension until the retaining mandrel (2) is fully in the holder (1) on the main boom.

• Insert the locking pin for the 12.5 m section

à p. 3 - 58.

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in position Secured;

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.8

Swinging the lattice extension when rigging

H

This section describes the swinging of the lattice extension during rigging.

If you want to swing the lattice extension for unrigging, then proceed in the opposite order.

When rigging the 13 m swing-away lattice extension, you must swing the 12.5 m (41 ft) section in front of the main boom head.

When rigging the 22 m two-stage swing-away lattice extension, you must also swing the 9 m section in front of the 12.5 m section.

H Swinging 12.5 m (41 ft) section in front of the main boom head

G

You can make it easier to swing the lattice extension by lowering the lattice extension a little for swinging out and raising it a little for swinging in.

When swinging always hold the lattice extension with a guide rope so that it can not swing around of its own accord.

• Secure the lattice extension with a guide rope on the head of the 12.5 m section;

à Securing lattice extension with cord, p. 3 - 59.

• Disconnect the connection between the 9 m section and the main boom or between the 12.5 m section and the main boom.

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

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3 - 61

Two-stage swing-away lattice extension 3.6 Description of rigging work

• Lower the lattice extension with the retaining mandrel out of the holder on the main boom.

• Swing the lattice extension until it is no longer above the run-up rail.

• Carefully lower the lattice extension from the control unit on the foot of the 12.5 msection until it starts to swing out.

If a helper is holding the guide rope, he can now swing the lattice extension in front of the main boom head.

If you are alone and have attached the guide rope to the crane when securing, the lattice extension now swings only until the guide rope is tight.

You can now swing the lattice extension with the guide rope in front of the main boom head.

Swinging the 9 m section in front of the 12.5 m section

The swinging procedure during rigging is described below. Proceed in the opposite order for unrigging.

Before you swing the 9 m section in front of the 12.5 m section to rig the 22 m two-stage swing-away lattice extension, the 12.5 m section must be lokked in front of the main boom head; p. 3 - 53.

à

• Disconnect the connection between the 9 m section and the 12.5 m section;

à Connections in the middle area, p. 3 - 46.

• Swing the 9 m section on the guide rope in front of the head of the 12.5 m section.

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Proceed in the opposite order for unrigging.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.9

Run-up rail There is a foldable angled plane in the run-up rail. The angled plane can be folded into both the Rigging and Unrigging positions.

Rigging position

• Unscrew the screw (1) until the angled plane (2) is tilted slightly downwards.

Now the angled plane is in the Rigging position.

Unrigging position

• Screw in the screw (1) until the angled plane (2) is tilted upwards.

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Now the angled plane is in the Unrigging position.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.10

Swinging the lattice extension onto the main boom head This section describes how the lattice extension is swung – onto the main boom head for rigging and – onto the main boom basic section for unrigging.

The lattice extension must be swung out of the transport position onto the main boom head so that the swinging connection can be made between the 12.5 m section and the main boom head.

Requirements

– The lattice extension is in transport position when the lattice extension is folded at the side; Transport condition with lattice extension folded at the side, p. 3 - 37.

– The required connections between the lattice extension sections are disconnected under each other or between the lattice extension sections and the main boom.

à

Swinging lattice extension When swung, the lattice extension rolls on the run-up rail, turns around the retaining mandrel (3) and becomes attached at the front at the stop (1).

The stop is set at the factory so that the bearing points (2) now align.

If the bearing points do not align, you can adjust the stop:

• Swing the lattice extension until the bearing points (2) align and make the swinging connection on the right side of the main boom head; p. 3 - 48.

à

• Unscrew or screw in the screw (1) until there is about a 2 mm (0,08 inch) gap between the screw head and the strut (3).

section until it is at the front at the stop (1); head, p. 3 - 48.

à Connections on main boom

• When unrigging push the lattice extension along the stop rail until it stops at the basic section.

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• When rigging pull the lattice extension at the back away from the basic

Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.11

Electrical connection on the lattice extension The SLI, lifting limit switch, lowering limit switch and the control system for derricking the lattice extension are connected via the electrical connection on the lattice extension.

13 m swing-away lattice extension

For the 13 mswing-away lattice extension the electrical connection is made or disconnected on the right side of the main boom head.

Establishing electrical connection

• Remove the short-circuit plug (3) from the socket (4) on the main boom.

• Remove the plug (2) from the dummy socket (1) and insert it in the socket (4) on the main boom head.

Disconnecting electrical connection

• Remove the plug (2) from the socket (4) on the main boom head and insert it in the dummy socket (1) on the 12.5 m section.

• Insert the short-circuit plug (3) in the socket

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(4) on the main boom.

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3 - 65

Two-stage swing-away lattice extension 3.6 Description of rigging work

• Check if the dummy plug (2) is inserted in the socket (1) at the front of the 12.5 m section.

22 m two-stage swing-away lattice extension

For the 22 m swing-away lattice extension an additional connection is made or disconnected between the 12.5 m section and the 9 m section as well as the electrical connection of the 13 m swing-away lattice extension.

• First make the electrical connection for the 13 m swing-away lattice extension;

à p. 3 - 65.

Establishing electrical connection

• Remove the dummy plug (2) from the socket (4) on the 12.5 m section.

• Remove the plug (3) from the dummy socket (1) on the 9 m section and insert it in the sokket (4) on the 12.5 m section.

• Insert the dummy plug in the dummy socket (1) on the 9 m section.

Disconnecting electrical connection

• Remove the plug (3) from the socket (4) on the 12.5 m section. tion and insert it in the socket (4) on the 12 m section .

• Insert the plug (3) in the dummy socket on the 9 m section.

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• Remove the dummy plug (2) from the dummy socket (1) on the 9 m sec-

Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.12

Establishing/disconnecting the hydraulic connection The hydraulic supply is required for derricking the lattice extension and consists of: – the hydraulic connection of the hose drum on the left side of the main boom; p. 3 - 40,

à

– and the hydraulic connection on the right side of the main boom head which is described in this section.

H

The connections are made via quick couplings.

Half couplings which belong together are colour coded.

Use the delivered levering tool to make the hydraulic connections; Connecting quick couplings with levering tool, p. 4 - 18.

à

Establishing hydraulic connection

• Remove the hose pipes (3) from the holders (1) on the 12.5 m section.

• Connect the hose pipes to the quick couplings (2) on the main boom head (observe colour code).

Disconnecting hydraulic connection

• Remove the hose pipes (3) from the quick couplings (2) on the main boom head.

• Squeeze the hose pipes into the holders (1)

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on the 12.5 m section.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.13

Folding out/in the deflection sheaves on the 12.5 m section To prevent the hoist rope dragging on the main boom or lattice extension during operation with the lattice extension or boom extension, the hoist rope is guided via deflection sheaves.

On the 12.5 m section there is a deflection sheave at the rear (1) and a deflection sheave at the front (2).

Both sheaves must be folded out:

– for operation with the 13 m swing-away lattice extension,

– for operation with the 22 m two-stage swing-away lattice extension.

For transportation both deflection sheaves must be folded in.

Folding rear deflection sheave Folding out deflection sheave

• Hold the deflection sheave by the handle (3) and remove the pin (2) from the bore (4).

• Fold the deflection sheave up and secure it with the pin in the bore (1).

• Secure the pin with a retaining pin.

Folding up deflection sheave

• Hold the deflection sheave by the handle (3) and remove the pin (2) from the bore (1).

• Fold the deflection sheave down and secure it with the pin in the bore (4).

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• Secure the pin with a retaining pin.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Folding front deflection sheave Folding out deflection sheave

• Unscrew the retaining pin on the pin (3).

• Hold the deflection sheave by the strut (1) and remove the pin (3) from the bore (2).

• Fold the deflection sheave up until the pin can be inserted through the bore (2) again.

• Insert the pin through the bore and secure it with a retaining pin.

Folding up deflection sheave

• Unscrew the retaining pin on the pin (3).

• Hold the deflection sheave by the strut (1) and remove the pin (3) from the bore (2).

• Fold the deflection sheave down until the pin can be inserted through the bore (2) again.

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• Insert the pin through the bore and secure it with a retaining pin.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.14

G

Positioning hoist rope Risk of accidents due to falling parts!

Always secure the hoist rope holding rollers and rods with retaining pins.

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

13 m swing-away lattice extension

22 m two-stage swing-away lattice extension

• Remove the hoist rope holding rollers and rods (1).

• Guide the hoist rope via the deflection sheaves (4), (3) and via the head sheave (2) on the 12.5 m section.

• Put all hoist rope holding rollers and rods back in place and secure these with retaining pins.

• Attach the hook tackle or the hook block. The hoist rope can be reeved

à p. 3 - 71.

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once or twice;

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Two-stage swing-away lattice extension 3.6 Description of rigging work

Possible reeving methods on the lattice extension

The hoist rope can be reeved once or twice.

Hook table max. load capacity of the hook block 12 t max. load capacity with GMK 5200/6220/6220-L 9.5 t reeving: single fall on the 13 mlattice extension or on the 22 m lattice extension

single-pulley hook block max. load capacity of the hook block 32 t max. load capacity with GMK 5200/6220/6220-L 19 t reeving: single or double fall on the 13 m lattice extension: single or double fall on the 22 m lattice extension: single fall

1 fall

1 fall

2 fall

The hoist rope can be reeved a maximum of two fall on the 13 m swingaway lattice extension.

The hoist rope can be reeved only one fall on the 22 m two-stage swingaway lattice extension.

à

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Reeving the hoist rope on the hook block; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.15

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

H Overriding connection on main boom

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

For operation with the lattice extension you must remove the lifting limit switch on the main boom and override the connection.

• Insert the short-circuit plug (1) in the socket for the connection of the lifting limit switch.

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The connection is now overridden.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

On the 13 m swing-away lattice extension

• Place the lifting limit switch (4) in the holder (5) and secure it with a retaining pin.

• Remove the short-circuit plug (2) from the socket (1).

• Connect the lifting limit switch on the socket (1) by guiding the cable upwards through the opening in the sheet behind the strut (3).

• When rigging you must insert the short-circuit plug (2) back in the socket (1).

On the 22 m twostage swing-away lattice extension

H

For operation with the 22 m two-stage swing-away lattice extension the connection for the lifting limit switch on the 12.5 m section must be overridden with a short-circuit plug.

• Place the lifting limit switch (2) on the shackle (1) and secure it with a retaining pin.

• Connect the lifting limit switch on the socket (3).

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When unrigging close the socket (3) with the protective cap.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.16

Anemometer on the lattice extension

H

The same anemometer is used for lattice extension and main boom.

On the 13 m swing-away lattice extension

• Secure the anemometer (3) to the holder (2) on the head of the 12.5 m section and secure it with a retaining pin.

• Insert the plug (1) of the connecting cable in the distribution box on the head of the 12.5 m section.

On the 22 m twostage swing-away lattice extension

• Attach the anemometer (1) to the holder (2) on the head of the 9 m section and secure it with a retaining pin.

• Insert the plug (3) of the connecting cable in

H 3 - 74

You must remove the anemometer before unrigging the lattice extension.

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the distribution box on the head of the 9 m section.

Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.17

Derricking lattice extension Before derricking the lattice extension set an SLI rigging code or a SLI code for work with the lattice extension.

When rigging

To derrick the lattice extension when rigging there are two control units each with two pushbuttons on the 12.5 m section.

• To raise press the top pushbutton Raise lattice extension (1).

• To lower press the bottom pushbutton Lower lattice extension (2).

During operation

During operation the lattice extension is derricked from the crane cab.

_ • • z

Press the Preselection of derricking control lever function / telescoping / derrick lattice extension rocker switch down.

The indicator lamp Right control lever in derrick lattice extension function lights up and you can derrick the lattice extension with the right control lever.

• To raise press the right control lever to the left.

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• To lower press the right control lever to the right.

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Two-stage swing-away lattice extension 3.6 Description of rigging work

3.6.18

G

Transportation on a separate vehicle Attach the lattice extension only at the prescribed slinging points and always use lifting gear with sufficient load bearing capacity. This prevents the Slinging lattice extension falling and injuring people while loading; points, p. 3 - 9.

à

Place the lattice extension for transportation on the supports (1) on the head and foot of the 12.5 m section.

• Always secure the lattice extension on the separate vehicle with belts as well to prevent slipping and overturning.

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S

Risk of damaging the lattice extension!

Always secure the lattice extension by tying it down with suitable belts when it is transported on a separate vehicle. This prevents the two-stage swing-away lattice extension tipping and becoming damaged during transportation.

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Two-stage swing-away lattice extension 3.7 Raising the setting down the main boom with rigged lattice extension

3.7

Raising the setting down the main boom with rigged lattice extension

H

G H

The information in this section also applies to raising and setting down the main boom with a rigged boom extension.

Risk of overturning with a reeved hook block on the main boom head!

If an SLI code has been entered for work with the lattice extension, the load is measured via pressure sensors on the lattice extension.

An additional load is not detected on the main boom here.

Therefore unreeve the hook block on the main boom head before working with the lattice extension. This prevents the SLI calculating with the wrong values and the truck crane tilting before the SLI switches off.

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

To raise and set down the following requirements must be met: – The SLI code for the actual rigging mode is set on the SLI with the 13 m swing-away lattice extension or 22 m two-stage swing-away lattice extension; operating instructions for the truck crane, part 2, chapter Crane operation, Section Operating the safe load indicator – Setting rigging mode.

à

– The current reeving of the hoist rope on the lattice extension is entered.

– Apart from the hook block there is no load on the lattice extension.

• Derrick in the main boom to raise.

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• Derrick out the main boom to set down.

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Two-stage swing-away lattice extension 3.7 Raising the setting down the main boom with rigged lattice extension

3.7.1

Telescoping with rigged lattice extension

S H

The main boom may be overloaded!

If you telescope the main boom with a rigged lattice extension or boom extension, you must not rotate the superstructure at the same time.

This prevents the main boom being subject to additional side forces and increased vibration and possibly becoming overloaded.

The information in this section also applies to telescoping with a rigged boom extension.

Telescoping with a load is released by the SLI only for loads which are below the values of the rigging programs.

Telescoping with a rigged lattice extension is released by the SLI only if the main boom is raised to an angle of approx. 75° - 80° (the exact angle depends on the length of the lattice extension; Rigging programs in the lifting capacity table).

If the main boom angle is too small for telescoping with the rigged lattice extension angle, the SLI shows the corresponding error message.

à

• Put down the load.

• Raise the main boom to an angle necessary according to the rigging pro-

à Rigging programs in the lifting capacity table).

gram (

• Telescope the main boom to the required length and observe the hook block when doing so; lower and raise it using the hoist.

Do not actuate the slewing gear when telescoping.

3.7.2

Operation with the lattice extension

If a hook block is reeved on the main boom during operation with the lattice extension, the loads given in the Lifting capacity tables decrease. The values which must be taken from the load capacities depend on the length of the lattice extension and the weight of the hook block and are entered in their own table in the Lifting capacity tables.

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H H

The information in this section also applies to operation with the boom extension.

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Two-stage swing-away lattice extension 3.7 Raising the setting down the main boom with rigged lattice extension

G H SLI shutdown

Risk of overturning with a reeved hook block on the main boom head!

If an SLI code has been entered for work with the lattice extension, the load is measured via pressure sensors on the lattice extension. An additional load is not detected on the main boom here.

Always determine the reduced load for the current rigging mode (given load minus value for the reduction with a reeved hook block) and lift only loads which are in accordance with the maximum reduced load.

This prevents the SLI calculating with the wrong values and the truck crane tilting before the SLI switches off.

The hoisting, lowering, slewing, derricking and telescoping movements of the main boom are done in the same way as when operating with the main boom. Telescoping is permitted only at main boom angles of approx. 75 80°, depending on the length of the lattice extension (exact value Rigging programs in the Lifting capacity table).

à

When working with the 13 m swing-away lattice extension or the 22 m twostage swing-away lattice extension, operation is always monitored by the SLI. SLI shutdowns can occur during lattice extension operation for the same reasons as with main boom operation; operating instructions for the truck crane, part 2, chapter Crane operation, Section Operating the safe load indicator – During crane work.

à

The angle of the lattice extension is also monitored and if the permitted angle of the lattice extension is not adhered to, the SLI switches off and shows a corresponding error message.

Procedure if the permissible wind speed is exceeded

Strong winds can overstrain the truck crane. Closely observe therefore the instructions in the Effect of wind on crane operation, Operating instructions GMK 5200/6220-L, part 2, chapter Crane work with the main boom – External influences during crane operation.

à

Procedure when exceeding the permissible wind speed during operation with the lattice extension or boom extension

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Wind speed less than 20 m/s

Wind speed greater than 20 m /s

• Put down the load.

• Put down the load.

• Turn the superstructure in

• Completely retract the main boom.

such a way that the main boom provides the wind with as little working surface as possible

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• Set the lattice extension down.

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Two-stage swing-away lattice extension 3.7 Raising the setting down the main boom with rigged lattice extension

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Two-stage swing-away lattice extension 3.8 Turning loads with the two-stage swing-away lattice extension

3.8

Turning loads with the two-stage swing-away lattice extension When turning loads it is necessary to employ a two-hook operation.

The only type of two-hook operation technically possible and protected by the SLI is described in this chapter using the turning of loads as an example.

G G H 3.8.1

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 gives protection.

Two-hook operation with the two-stage swing-away lattice extension is not permitted!

Risk of accidents due to overloading!

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

Position and function of the operating instruments required structions for the truck crane.

à Operating in-

Requirements The following description requires that: – the main hoist rope is reeved on the main boom and – the auxiliary hoist rope is reeved on the two-stage swing-away lattice extension and

07.11.2005

– the lifting limit switches for both hoisting gears are connected.

G

Risk of accidents due to overloading!

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

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

Operating instructions lattice extension GMK 5200/6220/6220-L

3 112 208 en

3 - 81

Two-stage swing-away lattice extension 3.8 Turning loads with the two-stage swing-away lattice extension

3.8.2

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

H

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

C¸ •

Switch both hoists off.

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

ü¸ •

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 position lamps.

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

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

C¸ • 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.

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

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

3 - 82

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Operating instructions lattice extension GMK 5200/6220/6220-L

07.11.2005

On the indicator lamps Hoists lamp II is flashing for the auxiliary hoist.

Two-stage swing-away lattice extension 3.8 Turning loads with the two-stage swing-away lattice extension

¸ •

Switch the main hoist on by pressing the Main hoist shutdown rocker switch up.

On the display lamps Hoists, lamp II is now lit for the auxiliary hoist and lamp I is flashing for the main hoist.

• Set the SLI code for operation with the telescopic swing-away lattice extension which is valid for the current rigging mode of the truck crane.

The SLI is thus set for two-hook operation; it now takes into consideration the reeving for the auxiliary hoist and the lifting capacity tables for the lattice extension.

H

In two-hook operation the loads given in the Lifting capacity table are reduced by the weight of both reeved hook blocks.

07.11.2005

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Operating instructions lattice extension GMK 5200/6220/6220-L

3 112 208 en

3 - 83

Two-stage swing-away lattice extension 3.8 Turning loads with the two-stage swing-away lattice extension

Turning load

S H H

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

Danger of accidents due to overloading!

Acceleration forces are an additional load on the crane.

For this reason, move the load during two-hook operation at the lowest possible speed! This prevents parts of the crane (two-stage swing-away lattice extension) from being overloaded.

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

If the load is on two hooks, you must not change the SLI code to Operation with main boom; it must be set to Operation with the lattice extension throughout the lifting process.

C0183

• Lift the load fully with the lattice extension.

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

07.11.2005

as well.

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

3 - 84

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.8 Turning loads with the two-stage swing-away lattice extension

C0184

• Slacken the hoist rope on the lattice extension until the load is only han-

07.11.2005

ging from the hook block on the main boom.

Turning the load is thus completed.

Operating instructions lattice extension GMK 5200/6220/6220-L

3 112 208 en

3 - 85

Two-stage swing-away lattice extension 3.8 Turning loads with the two-stage swing-away lattice extension

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Blank Page

3 - 86

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

3.9

Driving with rigged crane and two-stage swing-away lattice extension installed This section describes how to move the truck crane with an installed counterweight and rigged two-stage swing-away lattice extension on the building site.

G G 3.9.1

Risk of accidents!

It is forbidden to move the truck crane with a suspended load.

Put the load down before you move the truck crane.

Secure the hook block so that it cannot swing.

Risk of overturning!

Before a rigged crane can be driven the superstructure must be locked and the slewing gear permanent brake must be engaged.

Driving route The route must be a flat, even surface. The level adjustment system cannot compensate for uneven surfaces. If the surface pressure of the tyres exceeds the permissible load on the ground, the surface pressure must be increased using packing made of durable material (e.g. wooden planks).

à

07.11.2005

S

Risk of tyre damage!

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

The truck crane may only be moved if the tyres have been inflated to the required air pressure; operating instructions for the truck crane, Part 2, Chapter Technical information, Section Carrier – Tyres.

Do not reduce the tyre pressure!

Operating instructions lattice extension GMK 5200/6220/6220-L

3 112 208 en

3 - 87

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

3.9.2

Rigging mode and axle loads GMK 5200 The vehicle may only be moved under certain circumstances. The main boom and the lattice extension must be moved to a specific position, depending on the installed counterweight. The tables on the following pages provide an overview of the possible settings.

S

Danger of damage to the axle lines!

Always move the main boom and the lattice extension to the prescribed position before you move the rigged truck crane. The permitted loads on the axle lines are exceeded if the boom is in a position which deviates from the prescribed position.

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

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

07.11.2005

S

Risk of accidents if SLI is overridden!

Always set the SLI rigging code corresponding to the current rigging mode when you derrick the main boom into the prescribed position. Do not override the SLI; the prescribed positions in the following tables all lie within the areas which are permitted according to the Lifting capacity tables. The truck crane safe load indicator does not function when the SLI is overridden!

3 - 88

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

0/0/0/0/0

80

0/0/0/0/0

15

0/0/0/0/0

88

0.5 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0.5 / 0 / 0 / 0

15

0/0/0/0/0

70

64,0

0/0/0/0/0

55

70,0

0/0/0/0/0

50

14,0 22,5 33,5 44,0

1)

2)

Main Boom position1)

rear

15

Axle load 2) in t

front

0/0/0/0/0

10,5

Lattice extension angle in °

Main boom angle in °

All of the axle loads in the following table refer to a driving mode with the basic unit and a 32 t hook block reeved on the lattice extension; larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

13 m swing-away lattice extension

front

12,0

19,0

rear

13,0

17,5

front

11,5

21,0

rear

14,0

17,5

front

14,5

21,0

rear

16,5

18,0

front

17,5

22,0

rear

20,0

18,0

front

19,0

25,5

rear

23,5

18,5

5

rear

24,5

26,0

5

rear

26,0

27,5

5 5 5 5 5

Boom position at rear = Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

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

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Operating instructions lattice extension GMK 5200/6220/6220-L

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3 - 89

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

0/0/0/0/0

80

0/0/0/0/0

15

0/0/0/0/0

88

0.5 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0.5 / 0 / 0 / 0

15

0/0/0/0/0

80

64,0

0/0/0/0/0

60

70,0

0/0/0/0/0

60

14,0 22,5 33,5 44,0

1)

Main Boom position1) front

12,5

18,0

rear

13,0

17,5

front

12,0

21,0

rear

14,0

18,0

front

15,5

20,0

rear

16,5

18,0

front

18,5

21,0

rear

20,0

18,5

front

19,5

24,0

rear

23,0

19,0

5

rear

25,5

25,5

5

rear

27,5

26,0

5 5 5 5 5

Boom position at rear = Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

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

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2)

rear

15

Axle load 2) in t

front

0/0/0/0/0

10,5

Lattice extension angle in °

Main boom angle in °

All of the axle loads in the following table refer to a driving mode with the basic unit and a 12 t hook tackle reeved on the lattice extension; larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

22 m two-stage swing-away lattice extension

3 - 90

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

3.9.3

Rigging mode and axle loads GMK 6220 The vehicle may only be moved under certain circumstances. The main boom and the lattice extension must be moved to a specific position, depending on the installed counterweight. The tables on the following pages provide an overview of the possible settings.

S

Danger of damage to the axle lines!

Always move the main boom and the lattice extension to the prescribed position before you move the rigged truck crane. The permitted loads on the axle lines are exceeded if the boom is in a position which deviates from the prescribed position.

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

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

S

Risk of accidents if SLI is overridden!

Always set the SLI rigging code corresponding to the current rigging mode when you derrick the main boom into the prescribed position. Do not override the SLI; the prescribed positions in the following tables all lie within the areas which are permitted according to the Lifting capacity tables. The truck crane safe load indicator does not function when the SLI is overridden!

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Operating instructions lattice extension GMK 5200/6220/6220-L

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3 - 91

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

22,5

33,5

44,0

64,0

70,0

80

0/0/0/0/0

15

0/0/0/0/0

80

0.5 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0.5 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 1.0 / 1.0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 1.0 / 1.0 / 0

15

0/0/0/0/0

80

1)

2)

5

5

5

5

5

5

5

Boom position at rear =

Main Boom position1)

Lattice extension angle in °

Main boom angle in °

0/0/0/0/0

5

front

8,0

15,0

rear

8,0

15,0

front

7,5

15,5

rear

8,5

15,0

front

12,0

14,5

rear

9,0

15,5

front

15,0

15,0

rear

11,0

17,0

front

14,5

18,0

rear

13,5

18,5

front

15,5

20,0

rear

16,0

19,5

front

19,5

23,0

rear

20,5

22,5

front

17,5

26,0

rear

22,0

23,5

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

on 1st and 2nd axle line on 3rd, 4th, 5th and 6th axle line

s 3 - 92

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Operating instructions lattice extension GMK 5200/6220/6220-L

07.11.2005

14,0

15

rear

10,5

0/0/0/0/0

Axle load 2) in t

front

8,9

All of the axle loads in the following table refer to a driving mode with the basic unit and a 32 t hook block reeved on the lattice extension; larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

13 m swing-away lattice extension

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

14,0

22,5

33,5

44,0

64,0

70,0

0/0/0/0/0

80

0/0/0/0/0

15

0/0/0/0/0

80

0.5 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0.5 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 1.0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 1.0 / 1.0 / 0

15

0/0/0/0/0

80

1)

5

5

5

5

5

5

5

5

Boom position at rear =

Main Boom position1) front

8,5

15,0

rear

8,0

15,0

front

8,0

15,5

rear

8,5

15,0

front

12,5

14,0

rear

9,0

16,0

front

15,5

15,0

rear

11,0

17,0

front

15,5

17,5

rear

13,5

18,5

front

16,5

19,5

rear

16,0

19,5

front

16,0

25,0

rear

20,5

22,5

front

18,5

25,0

rear

22,0

23,5

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

on 1st and 2nd axle line on 3rd, 4th, 5th and 6th axle line

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2)

Lattice extension angle in °

Main boom angle in ° 15

rear

10,5

0/0/0/0/0

Axle load 2) in t

front

8,9

All of the axle loads in the following table refer to a driving mode with the basic unit and a 12 t hook tackle reeved on the lattice extension; larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

22 m two-stage swing-away lattice extension

Operating instructions lattice extension GMK 5200/6220/6220-L

3 112 208 en

3 - 93

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

3.9.4

Rigging mode and axle loads GMK 6220-L The vehicle may only be moved under certain circumstances. The main boom and the lattice extension must be moved to a specific position, depending on the installed counterweight. The tables on the following pages provide an overview of the possible settings.

S

Danger of damage to the axle lines!

Always move the main boom and the lattice extension to the prescribed position before you move the rigged truck crane. The permitted loads on the axle lines are exceeded if the boom is in a position which deviates from the prescribed position.

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

• Slew the superstructure into the position required (0° to the rear or 180° to the front).

! •

Lock the superstructure. The Counterweight locked indicator lamp must be lit.

• Derrick the main boom to 82°.

• Fully retract the main boom.

• Set a lattice inclination of 5°.

0° to the rear for the superstructure position

The tables on the following pages allocate a Telescoping rigging code and a Derricking rigging code for each counterweight combination to the different lattice extensions.

• Enter the Telescoping rigging code for the lattice extension currently rigged (e.g. 790 on the SLI for rigged 13 m lattice extensions and counterweight combinations 44.0 t).

07.11.2005

H

If SLI shutdown then occurs: – The lattice inclinations does not correspond to the specified angle, or – The current load exceed the maximum vpermitted value (e.g. a too large hook block has been reeved).

3 - 94

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

180° to the front for the superstructure position

G

The tables on the following pages allocate a Telescoping rigging code and a Derricking rigging code for each counterweight combination to the different lattice extensions.

Danger of accidents due to overridden SLI! The position required for the main boom and lattice extension in order to move the crane is partly outside the permitted working range. You should therefore always enter the appropriate Telescoping rigging code or Derricking rigging code before carrying out the corresponding crane movements.

Never override the SLI.

Telescoping the main boom

• Enter the Telescoping rigging code for the lattice extension currently rigged (e.g. 790 on the SLI for rigged 13 m lattice extensions and counterweight combinations 44.0 t).

• Telescope the main boom as required according to the following tables.

Derricking the main boom

• Enter the Telescoping rigging code for the lattice extension currently rigged (e.g. 780 for a rigged 13 m lattice extension and counterweight combination of 44.0 t).

• Derrick the main boom to the required angle according to the following tables.

07.11.2005

s

Operating instructions lattice extension GMK 5200/6220/6220-L

3 112 208 en

3 - 95

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

15

0/0/0/0/0

590

–

82

1.0 / 0 / 0 / 0 / 0

690

680

15

0/0/0/0/0

690

–

82

1.0 / 0 / 0 / 0 / 0

790

780

15

0/0/0/0/0

790

–

82

1.0 / 1.0 / 0 / 0 / 0

890

880

15

0/0/0/0/0

890

–

82

1.0 / 1.0 / 0 / 0 / 0

990

980

15

0/0/0/0/0

990

–

82

1)

5

5

5

5

front

13.5

17.0

rear

11.5

18.0

front

17.5

18.0

rear

14.0

19.5

front

14.0

22.0

rear

16.5

21.0

front

18.0

25.0

rear

21.0

23.5

front

15.5

28.0

rear

22.5

24.5

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

on 1st and 2nd axle line on 3rd, 4th, 5th and 6th axle line

07.11.2005

2)

Boom position at rear =

5

Main Boom position1)

580

Lattice extension angle in °

590

rear

70.0

0.5 / 0 / 0 / 0 / 0

Axle load 2) in t

front

64.0

Main boom angle in °

44.0

derricking

33.5

Rigging code for telescoping

22.5

All of the axle loads in the following table refer to a driving mode with the basic unit and a 32 t hook block reeved on the lattice extension; larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

13 m swing-away lattice extension

3 - 96

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

15

0/0/0/0/0

591

–

82

1.0 / 0 / 0 / 0 / 0

691

681

15

0/0/0/0/0

691

–

82

1.0 / 0 / 0 / 0 / 0

791

781

15

0/0/0/0/0

791

–

82

1.0 / 1.0 / 0 / 0 / 0

891

881

15

0/0/0/0/0

891

–

82

1.0 / 1.0 / 0 / 0 / 0

991

981

15

0/0/0/0/0

991

–

82

1)

5

5

5

5

front

16.5

15.5

rear

11.5

18.0

front

19.5

17.0

rear

14.0

19.5

front

16.0

21.5

rear

16.0

21.0

front

20.5

24.0

rear

21.0

24.0

front

18.0

27.0

rear

22.5

25.0

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

on 1st and 2nd axle line on 3rd, 4th, 5th and 6th axle line

07.11.2005

2)

Boom position at rear =

5

Main Boom position1)

581

Lattice extension angle in °

591

rear

70.0

0.5 / 0 / 0 / 0 / 0

Axle load 2) in t

front

64.0

Main boom angle in °

44.0

derricking

33.5

Rigging code for telescoping

22.5

All of the axle loads in the following table refer to a driving mode with the basic unit and a 12 t hook tackle reeved on the lattice extension; larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

22 m two-stage swing-away lattice extension

Operating instructions lattice extension GMK 5200/6220/6220-L

3 112 208 en

3 - 97

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

3.9.5

Driving the rigged crane

Engaging the slewing gear permanent brake

Before the truck crane is moved, the superstructure must be locked to the carrier; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Checking the truck crane before working with the crane – Mechanical superstructure lock.

à

! • • Y

H

Check that the superstructure is locked. The Counterweight locked indicator lamp must be lit.

Apply the slewing gear permanent brake and switch off the Slewing function to prevent inadvertent operation.

To do this push down the Slewing gear permanent brake rocker switch.

The Slewing gear permanent brake applied indicator lamp lights up when the slewing gear permanent brake is applied.

If the crane engine stops the slewing gear permanent brake is automatically applied.

• Retract the outrigger cylinders until the wheels are just above the ground.

Retracting the outrigger

G

Risk of overturning!

To reduce the risk of the truck crane overturning do not raise the outrigger pads more than 5 to 10 cm off the ground. Leave the outrigger beams extended.

Switching over the suspension locking system

u

• Switch the suspension locking system off. To do this push up the Suspension locking system rocker switch. The Suspension locking system indicator lamp must go out.

• Retract the outrigger cylinders until the truck crane is approximately at on-the-road level.

u •

Activate the suspension locking system again. To do this push down the Suspension locking system rocker switch. The Suspension locking system indicator lamp lights up when the suspension system is locked.

G 3 - 98

Risk of overturning!

To reduce the risk of the crane overturning do not raise the outrigger pads more than 5 to 10 cm (2 to 4 inch) off the ground. Leave the outrigger beams extended.

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Operating instructions lattice extension GMK 5200/6220/6220-L

07.11.2005

• Continue to retract the outrigger cylinders.

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

Switching on separate steering

Before driving with the rigged crane you must switch on separate steering:

• Switch on the Level adjustment system key switch.

C0018

b •

S

Switch on separate steering by releasing the Separate steering rocker switch and pressing it down.

Damage may occur to steering linkage!

Before driving with the rigged crane always switch on separate steering and steer the truck crane only when the vehicle is moving.

If separate steering is switched off or if you steer with the vehicle stationary the steering linkage may become damaged.

Driving

S H

Risk of tyre damage!

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

The truck crane may be moved only if tyre pressures are at the prescribed levels; operating instructions for the truck crane, Part 2, Chapter Technical information, Section Carrier – Tyres.

Do not reduce the tyre pressure!

à

The wind speed must be checked before the rigged truck crane is moved!

The same maximum permissible wind speeds apply as when working with the crane; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Crane work with main boom – External influences during crane operation – Effect of wind on crane operation.

à

• To move the truck crane, switch the transfer case to off-road gear;

à operating instructions for the truck crane, Part 2, Chapter Driving with the

truck crane, Section Off-road gear

• Switch to Gear 1; à operating instructions for the truck crane, Part 2, Chapter Driving with the truck crane, Section Automatic gearbox – Operation.

• Drive at only a very low speed!

• The turning radius should be as large as possible when turning corners!

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• Steer the truck crane only when it is moving and avoid sudden steering movements!

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3 - 99

Two-stage swing-away lattice extension 3.9 Driving with rigged crane and two-stage swing-away lattice extension installed

When the surface is uneven the truck crane must be raised with the outrigger cylinders, horizontally aligned and then re-lowered; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Outrigger / Retracting and Switching to suspension lokking system.

à

Extending the outriggers

à

Risk of overturning!

The truck crane must be raised until no wheels touch the ground!

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G

The truck crane must be on outriggers before beginning work with the craoperating instructions for the truck crane, Part 2, Chapter Rigging work, ne; Section Outrigger.

3 - 100

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Two-stage swing-away lattice extension 3.10 Malfunctions

3.10

Malfunctions

3.10.1

Two-stage swing-away lattice extension malfunctions

Cause

Action

Two-stage swingaway lattice extension cannot be inclined

Hydraulic system not connected to left side of boom head

Connect the hydraulic system; p. 3 - 40.

Hydraulic system not connected to the right side of boom head

Connect the hydraulic system; p. 3 - 67.

Electrical connection not connected to right side of boom head

Connect the electrical connection; p. 3 - 65.

Two-stage swingaway lattice extension cannot be inclined and SLI indicates error message 5.02.05 or 5.02.6

Lattice extension is at the maximum or minimum permissible angle

With error message 5.02.5 Lower the lattice extension

Lifting limit switch on the 13 m oder 22 m lattice extension does not function

Lifting limit switch not connected

Connect lifting limit switch; p. 3 - 72.

No electrical connection between boom head and lattice extension or between 13 m section and 9 m section

Establish electrical connection; p. 3 - 65.

Short-circuit plug not inserted on main boom head terminal box

Insert short-circuit plug; p. 3 - 72.

When operating with a 22 m lattice extension or boom extension the short-circuit plug is not inserted on the head of the 12.5 m section.

Insert short-circuit plug; p. 3 - 72.

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Malfunction

Operating instructions lattice extension GMK 5200/6220/6220-L

à à

à

With error message 5.02.6 Raise the lattice extension

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à

à

à à

3 - 101

Two-stage swing-away lattice extension 3.10 Malfunctions

3.10.2

S

Malfunctions on the SLI You must halt crane operation immediately when SLI error messages appear!

Repairs to the SLI may only be carried out by properly qualified personnel.

Further information on this subject can be found in the operating instructions operating instructions for the truck crane, Part 2, Chapter Malfunctions on the superstructure, Section SLI malfunction.

à

The following table indicates the possible error messages when operating with the two-stage swing-away lattice extension as well as the cause of error and what you can do to remedy the situation.

à

The arrows ( ) in the table indicate the corresponding point in the operating instructions for the truck crane, Part 2, Chapter Malfunctions on the superstructure, Section SLI malfunction.

Error messages from Error group 1, Sensors Error message 1.10. 1

Cause Two-stage swing-away lattice extension angle sensor A does not react.

Remedy

à Check supply line; If line is O.K., angle sensor A,

à Shut of luffing jib; Notify CraneCARE.

à

Shut of luf1.10. 2...6 Two-stage swing-away lattice Angle sensor A, extension angle sensor A indi- fing jib; Notify CraneCARE. cates an error Notify CraneCARE.

1.10. 8

Information message; You have switched off the two-stage swing-away lattice extension angle sensor A because of an error message.

1.11. 1

Differential angle indicator, Lattice extension does not react

1.11. 2...6 Differential angle indicator, Lattice extension indicates an error 1.11. 7

3 - 102

Message remains as long as the ignition is turned off.

à Check supply line; If line is O.K., à Switch off differential angle indicator; Notify CraneCARE.

à Switch off differential angle indicator; Notify CraneCARE.

Notify CraneCARE.

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1.10. 7

Two-stage swing-away lattice extension 3.10 Malfunctions

Message remains as long as the ignition is turned off.

1.11. 8

Information message; You have switched off the two-stage swing-away lattice extension angle sensor because of an error message.

1.12. 1

Two-stage swing-away lattice Check supply line; notify extension pressure sensor, lo- CraneCARE if necessary. wer chamber does not react

à

1.12. 2...6 Lattice extension pressure Notify CraneCARE. sensor, lower chamber indicates error 1.12. 7

Notify CraneCARE.

1.13. 1

Check supply line; notify Two-stage swing-away lattice CraneCARE if necessary. extension pressure sensor, upper chamber does not react

à

1.13. 2...6 Two-stage swing-away lattice Notify CraneCARE. extension pressure sensor, upper chamber indicates error

Error messages from error group 5, Range of cranes Error message

Cause

Remedy

Main boom angle during ope- Lower the main boom ration with lattice extension is too small.

5. 02. 5

Lattice extension angle too small

Lower the lattice extension

5. 02. 6

Lattice extension angle too large

Raise the lattice extension

5. 04. 5

An attempt was made to lock a telescope section at an intermediate length

Telescope to a fixed length

5. 07. 1

Force in derricking cylinder of lattice extension too great

Lower load

5. 07. 2

Load for derricking the lattice extension too great

Lower load

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5. 02. 4

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3 - 103

Two-stage swing-away lattice extension 3.10 Malfunctions

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Operating instructions lattice extension GMK 5200/6220/6220-L

Two-stage swing-away lattice extension 3.11 Maintenance plan

3.11

Maintenance plan

H

3.11.1

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

In addition, the following maintenance plans apply to the maintenance plans of the same name in the Maintenance manual of the truck crane.

The same abbreviations are used in the Maintenance manual (e.g. Oh = Operating hours).

Maintenance plan M 1: monthly / after 100 Oh

M1 Maintenance work on the SUPERSTRUCTURE: monthly / after 100 Oh

Oil/lubricant Quantity (l)/ number

Designation

2

K

each 1

K

Luffing jib (additional equipment) – Lubricate joint on 12.5 m section;

à p. 3 - 110. à p. 3 - 110.

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– Lubricate derricking cylinder in 12.5 m section;

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3 - 105

Two-stage swing-away lattice extension 3.11 Maintenance plan

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Two-stage swing-away lattice extension 3.12 Table of lubricants

3.12

Table of lubricants

H

The lubricant chart in the following table applies to the maintenance of the two-stage swing-away lattice extension. If the table of lubricants in the Maintenance manual of the truck crane contains other lubricants under the same designation, use only those lubricants in this table for the two-stage swing-away lattice extension.

Lubricating point

K

Bearings

Type of lubrication

Use for repairs with grease

Designation in acc. with DIN 51502

Specification Classification

KP - L2K

DIN 51825

Lubricant type Viscosity range

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Designation

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3 - 107

Two-stage swing-away lattice extension 3.12 Table of lubricants

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Two-stage swing-away lattice extension 3.13 Maintenance work

3.13

Maintenance work

3.13.1

Modules in need of protection during cleaning work

Provide protection for the following electrical parts during cleaning work: Electric control box with plug connections

2

Angle sensor control box

3

Angle sensor control box

4

Pressure sensors

Also observe all instructions contained in the chapter titled Cleaning work of the Maintenance manual for the truck crane.

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H

1

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3 - 109

Two-stage swing-away lattice extension 3.13 Maintenance work

3.13.2

M1

Lubricating joint on 12.5 m section

The joints on both sides of the 12.5 m section are each lubricated via a lubricating nipple (1) at the pivot point.

• Use only lubricating grease according to the maintenance plan;

à p. 3 - 105.

• Clean the lubricating nipple and lubricate it with a grease gun.

• Also lubricate the joint on the other side.

3.13.3

Lubricate derricking cylinder in 12.5 m section

M1

The derricking cylinder in the 12.5 m section is lubricated on the head and foot axle via a lubricating nipple (1).

• Use only lubricating grease according to the maintenance plan;

à p. 3 - 105.

• Clean the lubricating nipple and lubricate it

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with a grease gun.

3 - 110

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4 4

Boom extension

4.1

Components and Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

1

4.1.1

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

1

4.2

Attachment points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

3

4.3

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

5

4.4

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

7

CHECK LIST: Rigging 30 m/38 m boom extension. . . . . . . . . . . . . . . . . . . . . . . 4 - 7 CHECK LIST: Unrigging 30 m/38 m boom extension . . . . . . . . . . . . . . . . . . . . . 4 - 10

4.5

Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13

4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 4.5.7

Preparing the truck crane for rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13 Installing/removing 8 m sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15 Installing/removing two-stage swing-away lattice extension for boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16 Hydraulic connection on the boom extension. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17 Electrical connection on the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20 Folding out/in deflection sheaves on the 8 m sections . . . . . . . . . . . . . . . . . . . 4 - 22 Placing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23

4.6

Driving with rigged crane and boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25

4.6.1 4.6.2 4.6.3 4.6.4 4.6.5

Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25 Rigging mode and axle loads GMK 5200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26 Rigging mode and axle loads GMK 6220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29 Rigging mode and axle loads GMK 6220-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 32 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 36

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4.4.1 4.4.2

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Operating instructions lattice extension GMK 5200/6220/6220-L

Boom extension 4.1 Components and Identification

4

Boom extension

4.1

Components and Identification

4.1.1

Identification The boom extension consists of the 22 m two-stage swing-away lattice extension and two boom extension sections.

The boom extension is designed for the truck crane with which it was delivered. The parts of the boom extension belonging to the truck crane have the same serial number as the truck crane.

All components are identified by serial number.

Both parts of the boom extension are identified by a serial number.

S H

S

Danger of malfunction and damage!

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

The SLI is set only for this boom extension.

This means that you can prevent malfunctions and damage.

For technical reasons the truck crane may be adjusted only with one boom extension.

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

Danger of damage if the boom extension has not been adjusted or if it has been incorrectly adjusted!

Have the matching of the boom extension carried out only by CraneCARE!

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4-1

Boom extension 4.1 Components and Identification

Serial numbers on the 8 m sections

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

4-2

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Boom extension 4.2 Attachment points

4.2

Attachment points

G

This section shows the slinging points of the 8 m sections.

Sling the sections to these slinging points only, as they then automatically have the correct centre of gravity. Only use sling gear with sufficient load Boom extension, p. 2 - 1. bearing capacity; weight of individual parts

à

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The 8 m sections have two slinging points (1) (each slightly offset on each side).

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4-3

Boom extension 4.2 Attachment points

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4-4

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Operating instructions lattice extension GMK 5200/6220/6220-L

Boom extension 4.3 Assembly

4.3

Assembly

0,5 m foot section 8 m part

12,5 m part

9 m part

30 m boom extension

0,5 m foot section 8 m part

8 m part

12,5 m part

9 m part

38 m boom extension

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H

The 12.5 m part consists of a fixed 2 m part and a luffing part 10.5 m.

The 0.5 m foot section serves as a connection between the main boom head and the boom extension. It is an integral part of the two-stage swing-away lattice extension.

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4-5

Boom extension 4.3 Assembly

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Blank Page

4-6

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Boom extension 4.4 Check lists for rigging work

4.4

Check lists for rigging work

4.4.1

CHECK LIST: Rigging 30 m/38 m boom extension

H

This checklist is not equivalent to complete operating instructions.

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

Requirements: – The truck crane is supported or the main boom is placed on the boom support.

– An auxiliary crane must be ready.

1. Prepare the truck crane for unrigging; ging, p. 4 - 13.

à Preparing the truck crane for rig-

2. Install and connect hose drum for hydraulic supply (if applicable); Installing hose drum, p. 3 - 39.

à

3. If the lattice extension is folded up at the side of the main boom, remoCHECK LIST: Unrigging 30 m/38 m boom ve the lattice extension: extension, p. 4 - 10.

à

4. Check the transport condition of the two-stage swing-away lattice extension; Transport condition with removed lattice extension, p. 3 - 37.

à

5. Installing 8 m sections in front of the main boom: For 30 m boom extension a 8 m section For 38 m boom extension both 8 m sections; Attachment points, p. 4 - 3; Installing/removing 8 m sections, p. 4 - 15.

à à

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4-7

Boom extension 4.4 Check lists for rigging work

6. Installing folded two-stage swing-away lattice extension in front of the 8 m section; Installing/removing two-stage swing-away lattice extension for boom extension, p. 4 - 16.

à

7. Establish connection between 9 m and 12.5 m sections; in the front area, p. 3 - 44.

à Connections

8. Swing the 9 m section in front of the 12.5 m section; Swinging the 9 m section in front of the 12.5 m section, p. 3 - 62.

à

9. Lock the 9 m section in front of the 12.5 m section; Connections on lattice extension, p. 3 - 55.

Relieving the load on bearing points, p. 3 - 53.

à à

10. Establish hydraulic connections; tension, p. 4 - 17.

à Electrical connection on the boom ex-

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11. Establish electrical connections; tension, p. 4 - 20.

à Hydraulic connection on the boom ex-

4-8

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Boom extension 4.4 Check lists for rigging work

12. Folding out deflection sheaves on all sections; Folding out/in the deflection sheaves on the 12.5 m section, p. 3 - 68.

Folding out/in deflection sheaves on the 8 m sections, p. 4 - 22.

à à

13. Place hoist rope on the 9 m section via all deflection sheaves and the Placing the hoist rope, p. 4 - 23. head sheave;

à

14. Move anemometer (additional equipment) from the head of the main Anemometer on the lattice extenboom to the head of the 9 m section; sion, p. 3 - 74.

à

15. Move lifting limit switch from the head of the main boom to the head of Lifting limit switch on the lattice extension, p. 3 - 72. the 9 msection;

à

à

operating instructions for 16. Reeve the hoist rope onto the hook block; the truck crane, Part 2, Chapter Rigging work, Section Reeving and unreeving the hoist rope.

17. Attach lifting limit switch weight and guide hoist rope through the weight; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Reeving and unreeving the hoist rope – Lifting limit switch on the main boom lifting limit switch weight.

à

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4-9

Boom extension 4.4 Check lists for rigging work

18. Enter SLI code according to Lifting capacity table for the actual rigging mode of the truck crane with the 30 m or 38 m boom extension; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Operation of the safe load indicator – Setting the rigging mode.

à

à p. 3 - 77. à p. 3 - 78.

Further working steps for raising the boom; Telescoping with rigged boom extension;

4.4.2

CHECK LIST: Unrigging 30 m/38 m boom extension

H

This checklist is not equivalent to complete operating instructions. There are accompanying instructions which are indicated by cross-references.

Observe the warning and safety information given there!

Requirements: – The truck crane is supported or the main boom is placed on the boom support.

– An auxiliary crane must be ready.

1. Prepare the truck crane for unrigging; ging, p. 4 - 13.

à Preparing the truck crane for rig-

2. Fully retract and set down main boom.

For GMK 6220: Turn the main boom to the rear or to the side.

3. Enter SLI code according to Lifting capacity table for the actual rigging mode of the truck crane with the 22 m two-stage swing-away lattice extension; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Operation of the safe load indicator – Setting the rigging mode.

à

4. Remove lifting limit switch weight and move lifting limit switch from the head of the 9 m section to the head of the main boom; Lifting limit switch on the lattice extension, p. 3 - 72.

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à

4 - 10

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Boom extension 4.4 Check lists for rigging work

à

5. Unreeve the hoist rope from the hook block; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope.

6. Remove anemometer (additional equipment); tice extension, p. 3 - 74.

à Anemometer on the lat-

7. Disconnect the electrical connection between the 9 m and 12.5 m secElectrical connection on the lattice extension, p. 3 - 65. tions;

à

8. Fold in the deflection sheaves on all sections of the boom extension; Folding out/in the deflection sheaves on the 12.5 m section, p. 3 - 68.

Folding out/in deflection sheaves on the 8 m sections, p. 4 - 22.

à à

9. Reel hoist rope up to the main boom head.

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4 - 11

Boom extension 4.4 Check lists for rigging work

10. Remove locking pins between 9 m section and 12.5 m section on the left side and remove the lower pin on the right side with the head (left 2 pins, right 1 pin); Connections on lattice extension, p. 3 - 55.

Relieving the load on bearing points, p. 3 - 53.

à à

11. Turn 9 m section sideways onto the 12.5 m section; Swinging the 9 m section in front of the 12.5 m section, p. 3 - 62.

à

12. Establish connection between 9 m and 12.5 m sections; in the middle area, p. 3 - 46.

à Connections

13. Remove folded two-stage swing-away lattice extension from the 8 m Installing/removing two-stage swing-away lattice extension for section; boom extension, p. 4 - 16.

à

14. Remove 8 m sections from the main boom: With 30 m boom extension one 8 m section With 38 m boom extension both 8 m sections; Attachment points, p. 4 - 3.

Installing/removing 8 m sections, p. 4 - 15.

à à

à Installing

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15. Remove hose drum for hydraulic supply (if applicable); hose drum, p. 3 - 39.

4 - 12

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Boom extension 4.5 Description of rigging work

4.5

Description of rigging work

4.5.1

Preparing the truck crane for rigging

Requirements for rigging

The following requirements must be met before rigging of the boom extension: – The two-stage swing-away lattice extension is attached to the side of the main boom and is in transport condition.

– The counterweight version required acc. to the Lifting capacity table for the planned operation when the lattice extension is rigged.

– The truck crane is supported with the prescribed outrigger span for the planned operation with the lattice extension according to the Lifting capacity table and is aligned horizontally.

– If the truck crane is equipped with two hoists with additional equipment, the hook block is unreeved on the hoist which is not used for working with the lattice extension. for GMK 5200 / 6220-L: – The main boom is fully retracted (0/0/0/0/0) and lowered to the horizontal. for GMK 6220: Before telescoping, – the superstructure must be turned to the side or to the rear – the lattice extension must be fully raised so that the bearing points between the main boom and the lattice extension align.

S

Risk of damage when setting down on the boom rest When the main boom is set down in the boom rest fully retracted or in such a way that the bearing points do not align, the driver's cab and the lattice extension could be damaged.

Therefore, slew the superstructure to the side or to the rear.

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4 - 13

Boom extension 4.5 Description of rigging work

Requirements for unrigging

If the following prerequisites are met, the boom with the lattice extension may be lowered into the horizontal; Raising the setting down the main boom with rigged lattice extension, p. 3 - 77.

à

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

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

– The double swing-away lattice extension is fully raised.

– The SLI code for operation with rigged boom extension has been entered. additional instructions for GMK 6220: – The superstructure must be turned to the rear or to the side.

S

Risk of damage when setting down on the boom rest When the main boom is set down in the boom rest fully retracted or in such a way that the bearing points do not align, the driver's cab and the lattice extension could be damaged.

Therefore, slew the superstructure to the side or to the rear.

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

4 - 14

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Boom extension 4.5 Description of rigging work

4.5.2

Installing/removing 8 m sections – When rigging the 30 m boom extension you must install a 8 m section in front of the main boom head.

– When rigging the 38 m boom extension you must install another 8 m section in front of the 8 m section you installed first.

H

An auxiliary crane must be used to install and remove the 8 m sections.

The securing pins (1) for the connection are in the holders on the foot of the 8 m sections and are secured with retaining pins.

Installing 8 m sections

• Sling the 8 m section on an auxiliary crane and lift it in front of the main boom head so that the bearing points (2) and (3) align on both sides.

• Insert the securing pins on both sides into the bearing points (2) and (3).

• Secure all pins with retaining pins.

• Install the second 8 m section for the 38 m boom extension in the same way in front of the first 8 m section.

Removing 8 m sections

• Sling the 8 m section on an auxiliary crane and lift it until the the load has been relieved on the bearing points (2) and (3).

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• Release the pins and knock them out of the bearing points (2) and (3) on both sides.

• Insert the pins into the holders on the foot of the 8 m sections and secure them with retaining pins.

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4 - 15

Boom extension 4.5 Description of rigging work

4.5.3

Installing/removing two-stage swing-away lattice extension for boom extension This section describes the installation and removal of the folded two-stage swing-away lattice extension.

You can also install the two-stage swing-away lattice extension which has been folded in front of the other in front of a 8 m section (e.g. when you are changing directly from the 22 m two-stage swing-away lattice extension to a boom extension).

H

An auxiliary crane must be used to install and remove the two-stage swingaway lattice extension.

The securing pins (1) for the connection are in the holders on the foot of the 12.5 m sections and are secured with retaining pins.

Installation

• Sling the two-stage swing-away lattice extension onto an auxiliary crane; Slinging points, p. 3 - 9.

à

• Lift the two-stage swing-away lattice extension in front of the 8 m section so that the bearing points (2) and (3) align on both sides.

• Insert the securing pins on both sides into the bearing points (2) and (3).

• Secure all the pins with retaining pins.

Removing

• Sling the two-stage swing-away lattice extension onto an auxiliary crane;

à Slinging points, p. 3 - 9.

• Lift the two-stage swing-away lattice extension until the bearing points are relieved.

• Release the pins and knock them out of the bearing points (2) and (3) on both sides.

• Insert the pins into the holders on the 12.5 m section and secure them with 07.11.2005

retaining pins.

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Boom extension 4.5 Description of rigging work

4.5.4

Hydraulic connection on the boom extension The hydraulic supply is required for derricking the lattice extension. If the hose drum has been removed, the hose drum connection on the left side of the main boom must be established first; p. 3 - 40.

à

H

The connections are made via quick couplings.

Half couplings which belong together are colour coded.

Connections on the 8 m sections At the rear of the 8 m sections there are two hydraulic hoses (1) with quick couplings.

These hydraulic hoses can be connected on the main boom head or on a second 8 m section.

For transportation the hydraulic hoses are clamped in the holders (2).

At the front of the 8 m sections there are two quick couplings (1).

Here you can connect the hydraulic hoses of the 12.5 msection or a second 8 m section.

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4 - 17

Boom extension 4.5 Description of rigging work

Establish hydraulic connections

Use the delivered levering tool to make the hydraulic connections; Connecting quick couplings with levering tool, p. 4 - 18.

à

For the 30 m boom extension

• Connect the hydraulic hoses of the 8 m section to the quick couplings on the main boom head.

• Connect the hydraulic hoses of the 12.5 m section to the front of the quick couplings on the 8 m section.

For the 38 m boom extension

• Connect the hydraulic hoses of the first 8 m section to the quick couplings on the main boom head.

• Connect the hydraulic hoses of the second 8 m section to the front of the quick couplings on the first 8 m section.

• Connect the hydraulic hoses of the 12.5 m section to the front of the quick couplings on the second 8 m section.

Connecting quick couplings with levering tool

A levering tool is supplied to make it easier to connect the quick couplings.

The loose half coupling (6) is pressed into the fixed half coupling (5) with the levering tool (1).

There are sleeves (4) placed on the retaining sheets of the fixed half couplings in which the levering tool is supported on the journals (3).

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The two journals are offset so that the levering tool can be inserted into the sleeve on the right or left, depending on the height of the fixed half coupling.

If the position of the fixed half couplings is mixed up (e.g. the higher half coupling on the right) you can fold the rocker (2) 180° up and turn the levering tool round.

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Boom extension 4.5 Description of rigging work

• Insert the levering tool in the sleeve (2) with a journal so that it is at the correct height for the fixed half couplings (3).

• Place the loose half coupling (4) on the fixed half coupling.

• Place the fork (5) on the loose half coupling.

• Push the lever (1) up. The loose half coupling is pressed into the fixed half

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coupling.

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4 - 19

Boom extension 4.5 Description of rigging work

4.5.5

Electrical connection on the boom extension This section describes the electrical connections on the 8 m sections.

To establish the electrical connection on the two-stage swing-away lattice extension Electrical connection on the lattice extension, p. 3 - 65.

à

Connections on the 8 m sections At the rear of the 8 m sections there is a cable with a plug (3).

You can connect the cable to the main boom head or a second 8 m section.

For transportation the cable is wound around the holders (1) and the plug is inserted in the dummy socket (2).

07.11.2005

At the front of the 8 m sections there is a plug socket (1).

Here you can connect the cable of the 12.5 m section or a second 8 m section.

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Boom extension 4.5 Description of rigging work

Establishing electrical connections

For the 30 m boom extension

• Connect the cable of the 8 m section to the socket on the main boom head.

• Connect the cable of the 12.5 m section on the socket at the front of the8 m section.

For the 38 m boom extension

• Connect the cable of the first 8 m section to the socket on the main boom head.

• Connect the cable of the second 8 m section to the socket at the front of the first 8 m section.

• Connect the cable of the 12.5 m section on the socket at the front of the

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second 8 m section.

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4 - 21

Boom extension 4.5 Description of rigging work

4.5.6

Folding out/in deflection sheaves on the 8 m sections This section describes only the folding in and out of the deflection sheave on the 8 m sections. To fold in and out the deflection sheaves on the 12.5 m section; Folding out/in the deflection sheaves on the 12.5 m section, p. 3 - 68.

à

There is a deflection sheave on every 8 m section. For operation with the boom extension you must fold out the deflection sheaves on all rigged 8 m sections.

For transportation you must fold in the deflection sheaves.

Folding out deflection sheave

• Hold the deflection sheave by the strut (1) and pull out the pin (3).

• Fold the deflection sheave up and secure it with the pin in the bore (2).

• Secure the pin with a retaining pin.

Folding in deflection sheave

• Hold the deflection sheave by the strut (1) and pull out the pin (3).

• Fold the deflection sheave down and insert the pin in the bore (2).

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• Secure the pin with a retaining pin.

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Boom extension 4.5 Description of rigging work

4.5.7

G

Placing the hoist rope Risk of accidents due to falling parts!

Always secure the hoist rope holding rollers and rods with retaining pins.

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

30 m boom extension

38 m boom extension

• Remove the hoist rope holding rollers and rods (1).

• Guide the hoist rope via the deflection sheaves (5), (4), (3) and via the head sheave (2) on the 9 m section for both boom extensions.

• Put all hoist rope holding rollers and rods back in place and secure these with retaining pins.

Attach the hook tackle. The hoist rope may only be reeved once;

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à p. 3 - 71.

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4 - 23

Boom extension 4.5 Description of rigging work

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Blank Page

4 - 24

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Operating instructions lattice extension GMK 5200/6220/6220-L

Boom extension 4.6 Driving with rigged crane and boom extension

4.6

Driving with rigged crane and boom extension This section describes how to move the truck crane with an installed counterweight and rigged two-stage swing-away lattice extension on the building site.

G G 4.6.1

Risk of accidents!

It is forbidden to move the truck crane with a suspended load.

Put the load down before you move the truck crane.

Secure the hook block so that it cannot swing.

Risk of overturning!

Before a rigged crane can be driven the superstructure must be locked and the slewing gear permanent brake must be engaged.

Driving route The route must be a flat, even surface. The level adjustment system cannot compensate for uneven surfaces. If the surface pressure of the tyres exceeds the permissible load on the ground, the surface pressure must be increased using packing made of durable material (e.g. wooden planks).

à

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S

Risk of tyre damage!

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

The truck crane may only be moved if the tyres have been inflated to the required air pressure; operating instructions for the truck crane, Part 1, Chapter Technical information, Section Technical data – Carrier – Tyres.

Do not reduce the tyre pressure!

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4 - 25

Boom extension 4.6 Driving with rigged crane and boom extension

4.6.2

Rigging mode and axle loads GMK 5200 The vehicle may only be moved under certain circumstances. The main boom and the lattice extension must be moved to a specific position, depending on the installed counterweight. The tables on the following pages provide an overview of the possible settings.

S

Danger of damage to the axle lines!

Always move the main boom and the lattice extension to the prescribed position before you move the rigged truck crane. The permitted loads on the axle lines are exceeded if the boom is in a position which deviates from the prescribed position.

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

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

07.11.2005

S

Risk of accidents if SLI is overridden!

Always set the SLI rigging code corresponding to the current rigging mode when you derrick the main boom into the prescribed position. Do not override the SLI; the prescribed positions in the following tables all lie within the areas which are permitted according to the Lifting capacity tables. The truck crane safe load indicator does not function when the SLI is overridden!

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Boom extension 4.6 Driving with rigged crane and boom extension

The axle loads specified in the following tables refer to a driving mode with the basic unit and 32 t hook block reeved on the lattice extension, larger hook blocks must be unreeved.

Lattice extension angle in °

Main Boom position1)

0/0/0/0/0

15

5

front

12,5

25,0

0/0/0/0/0

80

5

rear

16,5

18,5

33,5

0/0/0/0/0

80

5

rear

20,0

19,0

44,0

0/0/0/0/0

70

5

rear

23,0

19,5

64,0

0/0/0/0/0

60

5

rear

24,5

27,5

70,0

0/0/0/0/0

60

5

rear

26,5

27,5

Counterweight in t

Main boom angle in °

Axle load 2) in t

Telescoping Tele.I/II/III/IV/V

30 m boom extension

22,5

1)

2)

Boom position at rear =

front

rear

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

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

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4 - 27

Boom extension 4.6 Driving with rigged crane and boom extension

The axle loads specified in the following tables refer to a driving mode with the basic unit and 32 t hook tackle reeved on the lattice extension, larger hook blocks must be unreeved.

Lattice extension angle in °

Main Boom position1)

0/0/0/0/0

15

5

front

15,0

21,5

0/0/0/0/0

80

5

rear

16,0

19,5

33,5

0/0/0/0/0

80

5

rear

19,5

20,0

44,0

0/0/0/0/0

80

5

rear

22,5

20,5

64,0

0/0/0/0/0

65

5

rear

24,5

27,5

70,0

0/0/0/0/0

65

5

rear

26,5

27,5

Counterweight in t

Main boom angle in °

Axle load 2) in t

Telescoping Tele.I/II/III/IV/V

38 m boom extension

22,5

1)

rear

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

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

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2)

Boom position at rear =

front

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Boom extension 4.6 Driving with rigged crane and boom extension

4.6.3

Rigging mode and axle loads GMK 6220 The vehicle may only be moved under certain circumstances. The main boom and the lattice extension must be moved to a specific position, depending on the installed counterweight. The tables on the following pages provide an overview of the possible settings.

S

Danger of damage to the axle lines!

Always move the main boom and the lattice extension to the prescribed position before you move the rigged truck crane. The permitted loads on the axle lines are exceeded if the boom is in a position which deviates from the prescribed position.

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

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

S

Risk of accidents if SLI is overridden!

Always set the SLI rigging code corresponding to the current rigging mode when you derrick the main boom into the prescribed position. Do not override the SLI; the prescribed positions in the following tables all lie within the areas which are permitted according to the Lifting capacity tables. The truck crane safe load indicator does not function when the SLI is overridden!

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4 - 29

Boom extension 4.6 Driving with rigged crane and boom extension

33,5

44,0

64,0

70,0

15

0/0/0/0/0

80

0.5 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 1.0 / 0 / 0

15

0/0/0/0/0

80

1)

5

5

5

5

Boom position at rear =

front

rear

front

12,5

16,5

rear

10,5

17,5

front

14,5

18,0

rear

13,0

19,0

front

15,0

20,5

rear

15,5

20,0

front

20,0

23,0

rear

20,0

23.0

front

17,5

26,0

rear

21,5

24,0

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

on 1st and 2nd axle line on 3rd, 4th, 5th and 6th axle line

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2)

5

Axle load 2) in t

Main Boom position1)

0.5 / 0 / 0 / 0 / 0

Lattice extension angle in °

Main boom angle in °

22,5

The axle loads specified in the following tables refer to a driving mode with the basic unit and 32 t hook block reeved on the lattice extension, larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

30 m boom extension

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Boom extension 4.6 Driving with rigged crane and boom extension

33,5

44,0

64,0

70,0

15

0/0/0/0/0

80

1.0 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 0 / 0 / 0

15

0/0/0/0/0

80

1.0 / 1.0 / 1.0 / 0 / 0

15

0/0/0/0/0

80

1)

5

5

5

5

Boom position at rear =

Axle load 2) in t

front

rear

front

15,0

15,0

rear

10,0

18,0

front

18,0

10,5

rear

12,5

19,0

front

12,0

21,0

rear

15,0

20,5

front

16,5

25,0

rear

19,5

23,5

front

22,0

24,0

rear

21,0

24,5

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

on 1st and 2nd axle line on 3rd, 4th, 5th and 6th axle line

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2)

5

Main Boom position1)

0.5 / 0 / 0 / 0 / 0

Lattice extension angle in °

Main boom angle in °

22,5

The axle loads specified in the following tables refer to a driving mode with the basic unit and 32 t hook block reeved on the lattice extension, larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

38 m boom extension

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4 - 31

Boom extension 4.6 Driving with rigged crane and boom extension

4.6.4

Rigging mode and axle loads GMK 6220-L The vehicle may only be moved under certain circumstances. The main boom and the lattice extension must be moved to a specific position, depending on the installed counterweight. The tables on the following pages provide an overview of the possible settings.

S

Danger of damage to the axle lines!

Always move the main boom and the lattice extension to the specified position before you move the rigged truck crane. The permitted loads on the axle lines are exceeded if the boom is in a position which deviates from the specified position.

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

• Slew the superstructure into the position required (0° to the rear or 180° to the front).

! •

Lock the superstructure. The Counterweight locked indicator lamp must be lit.

• Derrick the main boom to 82°.

• Fully retract the main boom.

• Set a lattice inclination of 5°.

0° to the rear for the superstructure position

The tables on the following pages allocate a Telescoping rigging code and a Derricking rigging code for each counterweight combination to the different lattice extensions.

• Enter the Telescoping rigging code for the lattice extension currently rigged (e.g. 792 for a rigged 30 m lattice extensions and counterweight combination of 44.0 t).

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H

If SLI shutdown then occurs: – The lattice inclinations does not correspond to the specified angle, or – The current load exceed the maximum vpermitted value (e.g. a too large hook block has been reeved).

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Boom extension 4.6 Driving with rigged crane and boom extension

180° to the front for the superstructure position

G

The tables on the following pages allocate a Telescoping rigging code and a Derricking rigging code for each counterweight combination to the different lattice extensions.

Danger of accidents due to overridden SLI! The position required for the main boom and lattice extension in order to move the crane is partly outside the permitted working range. You should therefore always enter the appropriate Telescoping rigging code or Derricking rigging code before carrying out the corresponding crane movements.

Never override the SLI.

Telescoping the main boom

• Enter the Telescoping rigging code for the lattice extension currently rigged (e.g. 792 for a rigged 30 m lattice extensions and counterweight combination of 44.0 t).

• Telescope the main boom as required according to the following tables.

Derricking the main boom

• Enter the Derricking rigging code for the lattice extension currently rigged (e.g. 782 for a rigged 30 m lattice extensions and counterweight combination of 44.0 t).

• Derrick the main boom to the required angle according to the following tables.

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4 - 33

Boom extension 4.6 Driving with rigged crane and boom extension

70.0

692

682

15

0/0/0/0/0

692

–

82

1.0 / 0 / 0 / 0 / 0

792

782

15

0/0/0/0/0

792

–

82

1.0 / 1.0 / 0 / 0 / 0

892

882

15

0/0/0/0/0

892

–

82

1.0 / 1.0 / 0 / 0 / 0

992

982

15

0/0/0/0/0

992

–

82

1)

5

5

5

Axle load 2) in t

front

rear

front

14.0

20.0

rear

14.0

20.0

front

19.0

20.0

rear

16.0

21.5

front

24.0

22.5

rear

20.5

24.0

front

22.0

25.0

rear

22.0

25.0

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

on 1st and 2nd axle line on 3rd, 4th, 5th and 6th axle line

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2)

Boom position at rear =

5

Main boom position1)

0.5 / 0 / 0 / 0 / 0

Lattice extension angle in °

Main boom angle in °

64.0

derricking

44.0

Rigging code for telescoping

33.5

The axle loads specified in the following tables refer to a driving mode with the basic unit and 32 t hook block reeved on the lattice extension, larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

30 m boom extension

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Boom extension 4.6 Driving with rigged crane and boom extension

70.0

693

683

15

0/0/0/0/0

693

–

82

1.0 / 0 / 0 / 0 / 0

793

783

15

0/0/0/0/0

793

–

82

1.0 / 0 / 0 / 0 / 0

893

883

15

0/0/0/0/0

893

–

82

1.0 / 1.0 / 0 / 0 / 0

993

983

15

0/0/0/0/0

993

–

82

1)

5

5

5

Axle load 2) in t

front

rear

front

17.5

18.5

rear

13.0

20.5

front

22.5

18.5

rear

15.5

22.0

front

15.5

27.0

rear

20.0

24.5

front

26.0

23.5

rear

21.5

25.5

Boom position at front =

0° position, boom over rear edge, undercarriage 180° position, boom over driver’s cab

Axle load front: rear:

on 1st and 2nd axle line on 3rd, 4th, 5th and 6th axle line

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2)

Boom position at rear =

5

Main boom position1)

0.5 / 0 / 0 / 0 / 0

Lattice extension angle in °

Main boom angle in °

64.0

derricking

44.0

Rigging code for telescoping

33.5

The axle loads specified in the following tables refer to a driving mode with the basic unit and 32 t hook block reeved on the lattice extension, larger hook blocks must be unreeved.

Telescoping Tele.I/II/III/IV/V

Counterweight in t

38 m boom extension

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4 - 35

Boom extension 4.6 Driving with rigged crane and boom extension

4.6.5

Driving the rigged crane

Engaging the slewing gear permanent brake

Before the truck crane is moved, the superstructure must be locked to the carrier; operating instructions for the truck crane – Superstructure lock.

à

! • Y •

H

Check that the superstructure is locked. The Counterweight locked indicator lamp must be lit.

Apply the slewing gear permanent brake and switch off the Slewing function to prevent inadvertent operation.

To do this push down the Slewing gear permanent brake rocker switch.

The Slewing gear permanent brake applied indicator lamp lights up when the slewing gear permanent brake is applied.

If the crane engine stops the slewing gear permanent brake is automatically applied.

• Retract the outrigger cylinders until the wheels are just above the ground.

Retracting the outrigger

G

Risk of overturning!

Make sure that the truck crane does not overturn when the outriggers are being retracted!

Retract all the outrigger cylinders as uniformly as possible!

Switching over the suspension locking system

u •

Switch the suspension locking system off. To do this push up the Suspension locking system rocker switch. The Suspension locking system indicator lamp must go out.

• Retract the outrigger cylinders until the truck crane is approximately at on-the-road level.

u •

Activate the suspension locking system again. To do this push down the Suspension locking system rocker switch. The Suspension locking system indicator lamp lights up when the suspension system is locked.

G 4 - 36

Risk of overturning!

To reduce the risk of the crane overturning do not raise the outrigger pads more than 5 to 10 cm (2 to 4 inch) off the ground. Leave the outrigger beams extended.

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07.11.2005

• Continue to retract the outrigger cylinders.

Boom extension 4.6 Driving with rigged crane and boom extension

Switching on separate steering

Before driving with the rigged crane you must switch on the separate steering:

• Switch on the level adjustment system key switch.

C0018

b •

S

Switch on separate steering by releasing the Separate steering rocker switch and pressing it down.

Damage may occur to steering linkage!

Before driving with the rigged crane always switch on separate steering and steer the truck crane only when the vehicle is moving.

If separate steering is switched off or if you steer with the vehicle stationary the steering linkage may become damaged.

Driving

S H

Risk of tyre damage!

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

The truck crane may only be moved if the tyres have been inflated to the required air pressure; operating instructions for the truck crane , Part 2, Chapter Technical information, Section Carrier – Tyres.

Do not reduce the tyre pressure!

à

The wind speed must be checked before the rigged truck crane is moved!

The same maximum permissible wind speeds apply as when working with the crane; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Crane work with main boom – External influences during crane operation – Effect of wind on crane operation.

à

• To move the truck crane, switch the transfer case to off-road gear;

à operating instructions for the truck crane, Off-road gear.

• Switch to Gear 1; à operating instructions for the truck crane, Automatic gearbox – Operation.

• The turning radius should be as large as possible when turning corners!

07.11.2005

• Steer the truck crane only when it is moving and avoid sudden steering movements!

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4 - 37

Boom extension 4.6 Driving with rigged crane and boom extension

When the surface is uneven the truck crane must be raised with the outrigger cylinders, horizontally aligned and then re-lowered; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Outrigger / Retracting and Switching to suspension lokking system.

à

Extending the outriggers

à

Risk of overturning!

The truck crane must be raised until no wheels touch the ground!

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G

The truck crane must be on outriggers before beginning work with the craoperating instructions for the truck crane, Part 2, Chapter Rigging work, ne; Section Outrigger.

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5 Auxiliary single-sheave boom top

5.1

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1

5.2

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

3

5.3

Installing the auxiliary single-sheave boom top. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

5

5.4

Reeving the hoist cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

7

5.5

Connecting the anchor-to-bracket-switch and anemometer . . . . . . . . . . . . . . . . 5 -

9

5.6

Operation with the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . 5 - 11

5.6.1

Turning loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12

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5

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Operating instructions lattice extension GMK 5200/6220/6220-L

Auxiliary single-sheave boom top 5.1 Identification

5

Auxiliary single-sheave boom top

5.1

Identification

S H

S

Danger of malfunction and damage!

Operate the truck crane only with the auxiliary single-sheave boom top that has the same serial number as the crane.

The SLI is only set for this auxiliary single-sheave boom top.

This prevents malfunctions and damage.

For technical reasons a truck crane may only be set with one auxiliary single-sheave boom top.

If you wish to use the auxiliary single-sheave boom top on several GROVE truck cranes, the auxiliary single-sheave boom top needs to be adapted to the relevant cranes and marked with all the serial numbers.

Danger of damage if the auxiliary single-sheave boom top has not been adjusted or if it has been incorrectly adjusted.

The auxiliary single-sheave boom top should only be adjusted by CraneCARE!

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The serial number can be found on the front (1) of the auxiliary single-sheave boom top.

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5-1

Auxiliary single-sheave boom top 5.1 Identification

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5-2

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Operating instructions lattice extension GMK 5200/6220/6220-L

Auxiliary single-sheave boom top 5.2 Installing/removing auxiliary single-sheave boom top

5.2

Installing/removing auxiliary single-sheave boom top

Installing boom top

• Use appropriate lifting tackle to secure boom top on connection eye and an auxiliary crane.

• Release and remove the swivel pin (1) from the bearing points.

• Use the auxiliary crane to lift the auxiliary single-sheave boom top in front of the head of the main boom.

• Insert the swivel pin (1) through the bear-ing points on the auxiliary single-sheave boom top and the main boom and secure with a retaining pin.

• Depending on the application, bring the auxiliary single-sheave boom top into transport position or working position; Installing the auxiliary single-sheave boom top, p. 5 - 5.

à

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Removing the auxiliary singlesheave boom top

The auxiliary single-sheave boom top must be disassembled for operation with: – boom extension (optional equipment) and – heavy load lattice extension (optional equipment).

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5-3

Auxiliary single-sheave boom top 5.2 Installing/removing auxiliary single-sheave boom top

• Use appropriate lifting tackle to secure boom top on connection eye and an auxiliary crane.

• Remove pins (2) and (3) from the bearing points and secure them in the holdings.

• Remove the centre pin (4) from the bearing point (5). Place and secure in holding.

• Remove the swivel pin (1) from the bearing points on the main boom and auxiliary single-sheave boom top.

• Use the auxiliary crane to lower boom top to the ground.

• Reinsert the swivel pin into the auxiliary single-sheave boom top.

All pins need to be secured with locking pins.

Transport

The disassembled boom top is ready for transport if – the swivel pin (1) has been inserted and secured with a locking pin.

– bolts (2) and (3) have been secured in their holdings.

• the centre bolt (4) is in the holding and secured there.

• the connecting cable of the anchor-to-brakket-switch has been wound onto the hook and the plug is in the dummy case.

Make sure not to damage the boom top when lowering it to the ground.

• Always prevent the boom top from slipping and overturning by securing it with additional belts.

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All pins need to be secured with locking pins.

Auxiliary single-sheave boom top 5.3 Installing the auxiliary single-sheave boom top

5.3

Installing the auxiliary single-sheave boom top

Installation for transport

S

Risk of damaging the electrics Always disconnect the electrical connections to the boom top before slewing sideways to the main boom.

This prevents the electrical connections to the boom top from being damaged while slewing.

• Disconnect the electrical connection of the anchor-to-bracket switch;

à p. 5 - 9.

• Remove both the pins (2) and (3) from the bearing points and secure them in the holdings.

• Remove the centre pin (4) from the bearing point (5). Insert and secure it in the holding.

• Turn the auxiliary single-sheave boom top around the swivel pin (1) to the side of the main boom.

All pins need to be secured with locking pins.

• Make sure the hook (3) on the boom top (1) is correctly lokked in the trap (2) on the main boom.

The auxiliary single-sheave boom top is now in transport position.

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5-5

Auxiliary single-sheave boom top 5.3 Installing the auxiliary single-sheave boom top

Installation for working position

• Pull the lever (4) on the boom top (1) downwards until the hook (3) in the trap (2) on the main boom is released.

• Slew the auxiliary single-sheave boom top in front of the main boom head.

• Insert and secure the pin (4) in the bearing point.

• Release bolts (2) and (3) in their holdings.

• Insert pins (2) and (3) into the bearing points on the main boom head and secure them.

• Establish the electrical connection for the

à

anchor-to-bracket-switch; Connecting the anchor-to-bracket-switch, p. 5 - 9.

All pins need to be secured with locking pins.

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The auxiliary single-sheave boom top is now in working position.

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Operating instructions lattice extension GMK 5200/6220/6220-L

Auxiliary single-sheave boom top 5.4 Reeving the hoist cable

5.4

Reeving the hoist cable

Installing the hoist cable

• Remove the rope securing sheaves and rods on the main boom head (1) and auxiliary single-sheave boom top (2).

• Place the hoist cable over the left-hand head sheave of the main boom while reeving.

• Insert the rope securing sheaves and rods into the respective bores and secure with the corresponding locking pins.

• Attach the rope end clamp to the hook tackle or hook block.

Reeving options on the auxiliary single-sheave boom top

For operation with the auxiliary single-sheave boom top the hoist cable may be reeved once at the most.

Hook tackle max. lifting capacity of the hook tackle 12 t max. lifting capacity of the GMK 5200/6220/6220-L 9,5 t Reeving: 1 times on the auxiliary single-sheave boom top

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single-pulley hook block max. lifting capacity of the hook block 32 t max. lifting capacity of the GMK 5200/6220/6220-L 9,5 t Reeving: 1 times on the auxiliary single-sheave boom top

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5-7

Auxiliary single-sheave boom top 5.4 Reeving the hoist cable

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Operating instructions lattice extension GMK 5200/6220/6220-L

Auxiliary single-sheave boom top 5.5 Connecting the anchor-to-bracket-switch and anemometer

5.5

Connecting the anchor-to-bracket-switch and anemometer

Connecting the anchor-to-bracketswitch

• Hang up the anchor-to-bracket-switch (7) on the bolt (6) on the auxiliary singlesheave boom top and secure with a locking pin.

• Remove the connection cable plug from the dummy case (5).

• Unwind the connection cable from the hooks (3).

• Remove the short-circuit plug (1) from the socket (2) on the main boom head.

6 7

• Put the connection cable plug into the socket (2).

• Put the hoist cable through the lifting limit switch weight.

If a hook block is also reeved on the main boom, connect the anchor-to-brakket-switch of the main hoist with the socket on the left side of the main boom head; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Rigging work on the main boom – Reeving and unreeving the hoist rope - Lifting limit switch on the main boom.

à

Disconnecting the anchor-to-bracketswitch

• Remove the connecting plug (4) from the socket on the main boom.

• Plug the short-circuit plug (1) into the socket (2).

• Wind the connecting cable of the anchor-tobracket-switch around the hooks (3) on the auxiliary single-sheave boom top.

• Plug the connecting plug (4) into the dummy case (5).

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5-9

Auxiliary single-sheave boom top 5.5 Connecting the anchor-to-bracket-switch and anemometer

• Connect the anemometer as described in the supplied à operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Anemometer.

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Connecting the anemometer

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Auxiliary single-sheave boom top 5.6 Operation with the auxiliary single-sheave boom top

5.6

Operation with the auxiliary single-sheave boom top If an auxiliary single-sheave boom top is folded on during operation with the main boom, the loads detailed in the Lifting capacity tables decrease by the weight of the auxiliary single-sheave boom top; Auxiliary single-sheave boom top, p. 2 - 1.

à

H SLI deactivation

Hoisting, lowering, rotating, derricking and telescoping the main boom are carried out as for operation with the main boom. The SLI enables telescoping only for main boom angles of approx. 75-80° (precise value Installation graphs in the lifting capacity table).

à

When working with the auxiliary single-sheave boom top, operation is monitored by the SLI. When operating with the auxiliary single-sheave boom top, SLI deactivations may occur for the same reasons as for operation with the main boom; operating instructions for the truck crane.

à

What to do if the permissible wind speed has been exceeded

Strong winds can overstrain the truck crane. It is therefore necessary to pay attention to the information in Effect of wind on crane operation in the operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Crane work with the main boom.

What to do if the permissible wind speed has been exceeded during operation with the auxiliary single-sheave boom top Wind speed below 20 m/s

Wind speed above 20 m /s

• Lower load to the ground.

• Lower load to the ground.

• Rotate the superstructure so • Retract main boom completely. that the main boom is expo- • Rest main boom with auxiliary singlesheave boom top in the boom support.

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sed to as little wind as possible.

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5 - 11

Auxiliary single-sheave boom top 5.6 Operation with the auxiliary single-sheave boom top

5.6.1

Turning loads Turning loads requires working with two-hook operation. Two-hook operation is permitted only in conjunction with a lattice extension.

The only kind of two-hook operation technically possible and safe due to SLI is described in this chapter using turning of loads as an example.

G G H Prerequisites

Risk of accidents due to overloading!

Hoisting loads with two hooks is only permissible if carried out according to the following instructions and diagrams!

If these instructions are not observed there is a risk of accidents due to overloading of individual truck crane parts. In that case, protection by means of SLI will not be possible.

Two-hook operation with the auxiliary single-sheave boom top is not permitted!

Risk of accidents due to overloading!

The load must always be raised completely starting with the weakest part (auxiliary single-sheave boom top).

Regarding position and function of necessary operating instruments; operating instructions for the truck crane, Part 2, Chapter Description of the truck crane – crane section, Section Functional description of the display and operating instruments.

à

The following description applies, providing – the main hoist rope is folded on the main boom and – the auxiliary hoist rope is folded on the auxiliary single-sheave boom top.

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G

Risk of accidents due to overloading!

The reeving on the main boom must be the same as or larger than the reeving on the auxiliary single-sheave boom top.

If this prerequisite is disregarded the main hoist rope and the main hoist will get overloaded.

5 - 12

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Operating instructions lattice extension GMK 5200/6220/6220-L

Auxiliary single-sheave boom top 5.6 Operation with the auxiliary single-sheave boom top

Setting the SLI

H

For the two-hook operation both hoists on the SLI need to be switched on.

It is recommendable to enter the reevings for both hoists right at the beginning. The values are saved and called up directly when changing over the hoists. This saves you entering the values during operation. Proceed as follows:

Cü • ü •

Switch off both hoists.

To do so press down the bottom part of the two rocker switches Disconnect auxiliary hoist and Disconnect main hoist.

Switch on main hoist.

To do so press top half of rocker switch Disconnect main hoist.

On the Hoists indicator lamps lamp I for the main hoist lights up.

• On the Reeving display, enter the number of reeved ropes of the main hoist rope on the main boom.

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

Cü •

Switch off both hoists.

To do so press down the bottom part of the two rocker switches Disconnect auxiliary hoist and Disconnect main hoist.

C •

Switch on auxiliary hoist.

To do so press top half of rocker switch Disconnect auxiliary hoist.

On the Hoists indicator lamps, lamp II (auxiliary hoist) flashes.

• On the Reeving display, enter the number of reeved ropes of the auxiliary 07.11.2005

hoist rope on the auxiliary single-sheave boom top.

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

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5 - 13

Auxiliary single-sheave boom top 5.6 Operation with the auxiliary single-sheave boom top

ü •

Switch on the main hoist by pressing the top half of rocker switch Disconnect main hoist.

On the Hoists indicator lamps, lamp II for the auxiliary hoist and lamp I for the main hoist flash.

• Set the SLI code for operation with auxiliary single-sheave boom top valid for the truck crane’s current installation condition.

The SLI for two-hook operation is now set; it considers the reeving for the auxiliary hoist and the lifting capacity tables for the auxiliary single-sheave boom top.

H Turning the load

S

For turning the load, proceed as follows.

Danger of accidents due to overloading!

Acceleration forces are an additional load on the crane.

For this reason, move the load during two-hook operation at the lowest possible speed! This prevents parts of the crane (two-stage swing-away lattice extension) from being overloaded.

As soon as the load is attached to two hooks, there will be slight variations in the Actual load display. These variations are on the safe side in terms of SLI, though.

As long as the load is attached to two hooks do not switch the SLI code to Operation with main boom; rather it must be set at Operation with auxiliary single-sheave boom top during the entire hoisting procedure.

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H H

Load measurement for two-hook operation is carried out via the pressure in the derricking cylinder of the main boom. This reduces the loads listed in the Lifting capacity table by the weight of both reeved hook blocks.

5 - 14

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Operating instructions lattice extension GMK 5200/6220/6220-L

Auxiliary single-sheave boom top 5.6 Operation with the auxiliary single-sheave boom top

• Lift the load completely with the auxiliary single-sheave boom top.

• Now sling load onto hook block of main boom aswell (do not do so at an earlier stage).

• Raise the load with the hook block on the main boom until both slinging

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points are at the same height.

• Give a little more hoist cable on the auxiliary single-sheave boom top until the load hangs from the hook block on the main boom only.

Turning the load is complete.

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5 - 15

Auxiliary single-sheave boom top 5.6 Operation with the auxiliary single-sheave boom top

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Operating instructions lattice extension GMK 5200/6220/6220-L

6 6

Heavy load lattice extension

6.1

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

1

6.1.1

Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

2

6.2

Checklists for rigging work on the heavy load lattice extension . . . . . . . . . . . . . 6 -

3

6.2.1 6.2.2 6.2.3 6.2.4 6.2.5

Overview of the required rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CHECKLIST: Mounting heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . 6 CHECKLIST: Removing heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . 6 CHECKLIST: Rigging the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . 6 CHECKLIST: Removing the heavy load lattice extension . . . . . . . . . . . . . . . . . . 6 -

3 4 5 6 8

6.3

Installation and rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11

6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7

Heavy load lattice extension in transport position . . . . . . . . . . . . . . . . . . . . . . . 6 - 11 Slewing the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12 Pin connections for operating the heavy load lattice extension . . . . . . . . . . . . 6 - 13 Working positions for the heavy load lattice extension . . . . . . . . . . . . . . . . . . . 6 - 14 Positioning the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17 Lifting limit switch on the heavy load lattice extension . . . . . . . . . . . . . . . . . . . 6 - 19 Transporting on a separate vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21

6.4

Raising and setting down the main boom with rigged heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23 Operation with the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25

6.5.1 6.5.2

Telescoping with rigged heavy load lattice extension . . . . . . . . . . . . . . . . . . . . 6 - 26 Turning loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 27

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6.5

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Heavy load lattice extension 6.1 Identification

6

Heavy load lattice extension For crane operation, the heavy load lattice extension is mounted in front of the main boom head. For transporting on open roads, it must be removed and set onto a separate vehicle.

Operating the heavy load lattice extension is permitted only with 1 or 2 fall reeved auxiliary hoist gear rope.

6.1

Identification The heavy load lattice extension is aligned to the truck crane with which it was delivered. The heavy load lattice extension has the same serial number as the truck crane to which it belongs.

S H

S

Danger of malfunction and damage!

Operate the truck crane only with the heavy load lattice extension which bears the same serial number as the crane.

The SLI is set only for this lattice extension. In this way you will avoid malfunctions and eventual damage.

For technical reasons a truck crane may only be set with one heavy load lattice extension.

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

Danger of damage if the heavy load lattice extension has not been adjusted or if it has been incorrectly adjusted!

Have the adjustment of the extension carried out only by CraneCARE at the respective location!

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6-1

Heavy load lattice extension 6.1 Identification

The heavy load lattice extension consists of four different parts. All parts are marked with the same serial number as the truck crane.

1 Strut member 2 Foot section 3 Upper tie member 4 Lower tie member The heavy load lattice extension is delivered as one unit with the parts bolted together.

6.1.1

G

Center of gravity In the following drawing, the center of gravity is shown for the rigging of the heavy load lattice extension.

Sling the extension such that it is tied down as indicated. Use only lifting gear with sufficient load capacity; Weight of the heavy load lattice extension p. 2 - 2

à

• Tie down the lattice extension in the 0° posi-

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tion such that it hangs horizontally level to the auxiliary crane.

6-2

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Heavy load lattice extension 6.2 Checklists for rigging work on the heavy load lattice extension

6.2

Checklists for rigging work on the heavy load lattice extension

6.2.1

Overview of the required rigging work There are different initial states for rigging the lattice extension, depending on whether the extension is – removed for on-road driving with a maximum 12 t axle load; CHECKLIST: Mounting heavy load lattice extension, p. 6 - 4,

à

– folded down on the side of the main boom; heavy load lattice extension, p. 6 - 6, – supposed to be folded onto the main boom; heavy load lattice extension, p. 6 - 8or

à CHECKLIST: Rigging the à CHECKLIST: Removing the

– supposed to be removed for on-road driving with a maximum 12 t axle CHECKLIST: Removing heavy load lattice extension, p. 6 - 5. load;

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à

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6-3

Heavy load lattice extension 6.2 Checklists for rigging work on the heavy load lattice extension

6.2.2

CHECKLIST: Mounting heavy load lattice extension

H

This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warning and safety information given there!

Prerequisites: – The truck crane is on outriggers or the main boom is placed on the boom support.

– The required counterweight is rigged.

– The heavy load lattice extension is at 0°.

– An auxiliary crane is available.

1. Sling the heavy load lattice extension onto the auxiliary crane; Center of gravity, p. 6 - 2.

à

2. Lift the heavy load lattice extension on the side of the main boom and establish a slewing connection between the lattice extension and the main boom; Swiveling lattice extension in front of main boom head, p. 6 - 12.

à

3. Swivel the heavy load lattice extension onto the side of the main boom and insert and secure locking pins at the bearing point between the exHeavy load lattice extension in transport position, tension and the boom; p. 6 - 11.

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à

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Heavy load lattice extension 6.2 Checklists for rigging work on the heavy load lattice extension

6.2.3

CHECKLIST: Removing heavy load lattice extension

H

This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warning and safety information given there!

Prerequisites: – The truck crane is on outriggers or the main boom is placed on the boom support.

– The heavy load lattice extension is at 0°.

– An auxiliary crane is available.

1. Sling the heavy load lattice extension onto the auxiliary crane; Center of gravity, p. 6 - 2.

à

2. Remove locking pins on both sides; heavy load lattice extension, p. 6 - 13.

à Pin connections for operating the

à Transporting

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3. Set heavy load lattice extension on a separate vehicle; on a separate vehicle, p. 6 - 21.

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6-5

Heavy load lattice extension 6.2 Checklists for rigging work on the heavy load lattice extension

6.2.4

CHECKLIST: Rigging the heavy load lattice extension

H

This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warning and safety information given there!

Prerequisites: – The heavy load lattice extension is bolted to the side of the main boom.

– The counterweight is rigged for operation with the heavy load lattice extension.

1. Fasten guide ropes.

2. Remove locking pins between the lattice extension and the main boom basic section; p. 6 - 11.

à

3. Swivel the lattice extension in front of the main boom head; Swiveling lattice extension in front of main boom head, p. 6 - 12.

à

4. Lock the lattice extension to the right and left side of the main boom; Pin connections for operating the heavy load lattice extension, p. 6 - 13.

à

5. Move the lifting limit switch to the head of the lattice extension and conLifting limit switch on the heavy load lattice extension, nect it there; p. 6 - 19.

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à

Heavy load lattice extension 6.2 Checklists for rigging work on the heavy load lattice extension

6. Move the heavy load lattice extension into the working position; Working positions for the heavy load lattice extension, p. 6 - 14.

à

7. Lay the auxiliary hoist rope over the sheave of the main boom and lattice extension; Positioning the hoist rope, p. 6 - 17.

à

à

8. Reeve the hoist rope on the hook block; operating instructions for the truck crane – Hoist rope/reeving on main boom.

9. Attach lifting limit switch weight and guide hoist rope through the operating instructions for the truck crane – Lifting limit switch weight; weight.

à

10. Install the anemometer on the main boom; the truck crane – Anemometer.

à operating instructions for

11. Enter the SLI code according to the Lifting capacity table for the actual rigging mode of the truck crane with the heavy load lattice extension; operating instructions for the truck crane – Rigging mode.

à

à

Further working steps for raising the boom; Raising and setting down the main boom with rigged heavy load lattice extension, p. 6 - 23.

Telescoping with rigged heavy load lattice extension; Telescoping with rigged heavy load lattice extension, p. 6 - 26.

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à

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6-7

Heavy load lattice extension 6.2 Checklists for rigging work on the heavy load lattice extension

6.2.5

CHECKLIST: Removing the heavy load lattice extension

H

This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warning and safety information given there!

Prerequisites: – Set the SLI code according to the Lifting capacity table.

1. Fully retract and set down main boom.

2. Remove lifting limit switch weight and separate the limit switch connection to the main boom; Removing the heavy load lattice extension, p. 6 - 20, operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Lifting limit switch weight.

à à

3. Unreeve the hoist rope from the hook block and roll it onto a drum; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope.

à

4. Heavy load lattice extension in 0° position; tice extension into the 0° position, p. 6 - 16.

à Moving the heavy load lat-

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5. Fasten the guide rope onto the head of the heavy load lattice extension.

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Heavy load lattice extension 6.2 Checklists for rigging work on the heavy load lattice extension

6. Remove locking pins between the heavy load lattice extension and main boom head; Pin connections for operating the heavy load lattice extension, p. 6 - 13.

à

H

If the heavy load lattice extension is to be removed for on-road driving, continue with CHECKLIST: Removing the heavy load lattice extension, p. 6 - 5.

à

7. Slew the heavy load lattice extension onto the main boom.

8. Insert and secure locking pins at the bearing points between the lattice Heavy load lattice extenextension and the main boom basic section; sion in transport position, p. 6 - 11.

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à

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Heavy load lattice extension 6.2 Checklists for rigging work on the heavy load lattice extension

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Heavy load lattice extension 6.3 Installation and rigging work

6.3

Installation and rigging work

6.3.1

Heavy load lattice extension in transport position The heavy load lattice extension is in transport position if – it is at 0°,

– the swivel pins (2) are inserted and secured, – the heavy load lattice extension is folded onto the side of the main boom basic section and

– the safety pin (1) is inserted and secured.

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G

Risk of accidents due to falling parts!

Always secure the pins both in the bearing points and in the holders using retaining pins.

This prevents unsecured pins from becoming loose, falling out and causing injuries.

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Heavy load lattice extension 6.3 Installation and rigging work

6.3.2

Slewing the heavy load lattice extension This section describes slewing the heavy load lattice extension – onto the main boom head when rigging and – onto the main boom basic section when removing.

The heavy load lattice extension must be slewed out of transport position to the front of the main boom head.

Prerequisites

– In transport position, the heavy load lattice extension is folded on the side of the main boom basic section; p. 6 - 11.

à

– The locking pin between the lattice extension and basic main boom section is inserted and secured.

H

When slewing always hold the lattice extension with a guide rope so that it can not swing around of its own accord.

Swiveling lattice extension in front of main boom head

G

Risk of accidents from lattice extension swinging of its own accord!

Always secure the heavy load lattice extension using a guide rope before removing the safety pin between the extension and the main boom basic section. Make sure that there are no people or objects in the slewing range of the lattice extension and always swing out the lattice extension with a guide rope from the base.

• Secure the heavy load lattice extension with a guide rope.

• Remove the safety pin between the lattice extension and the main boom

If a helper is holding the guide rope, he can now swing the lattice extension in front of the main boom head.

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basic section.

Heavy load lattice extension 6.3 Installation and rigging work

6.3.3

Pin connections for operating the heavy load lattice extension – Before slewing the heavy load lattice extension in front of the main boom head when rigging or – swinging the extension onto the main boom basic section for removal, you must create or release several connections.

The connections on the bearing points are made with pins.

The pins can be found in holders on the lattice extension and are secured there with retaining pins.

G

Risk of accidents due to falling parts!

Always secure the pins both in the bearing points and in the holders using retaining pins. This prevents unsecured pins from becoming loose, falling out and causing injuries.

• Pin the heavy load lattice extension on both sides to the main boom head.

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The pins can remain at the bearing points during operation.

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6 - 13

Heavy load lattice extension 6.3 Installation and rigging work

6.3.4

Working positions for the heavy load lattice extension Depending on requirements, the heavy load lattice extension can be installed in two different working positions.

Prerequisites

– The main boom is resting on the boom support.

– The heavy load lattice extension has been pinned to the front of the main boom head.

– 0° (transport position)

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– 25° position

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Heavy load lattice extension 6.3 Installation and rigging work

Moving the heavy load lattice extension into the 25° position

G

Risk of accidents due to falling chain hoist Always detach the chain hoist for setting working positions before operating with the heavy load lattice extension.

In this way you will avoid damaging the main boom with the chain hoist or causing injury should the hoist drop.

A chain hoist (3) is available for setting the working positions for the heavy load lattice extension.

• Attach the chain hoist at points 2 and 4.

• Use the winch to lift the lattice extension until the pins (1) are not bearing any weight.

• Remove the retaining pins from both lokking pins (1) and remove the lokking pins from their bearing points.

• Lower the lattice extension using the chain hoist until the bore holes in the tie member can be seen below.

• Reinsert the two pins into the bearing points and secure them with the retaining pins.

• Release the chain hoist and detach it when operating with the heavy load lattice extension.

• Place the hoist rope for the auxiliary hoist; 07.11.2005

à p. 6 - 17.

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Heavy load lattice extension 6.3 Installation and rigging work

Moving the heavy load lattice extension into the 0° position

G

Risk of accidents due to falling chain hoist Always detach the chain hoist for setting working positions before operating with the heavy load lattice extension.

In this way you will avoid damaging the main boom with the chain hoist or causing injury should the hoist drop.

• Remove the hoist rope from the lattice extension.

• Attach the chain hoist (3) at points 2 and 4.

• Use the chain hoist (3) to lift the lattice extension until the pins (1) are not bearing any weight.

• Remove the retaining pins from both lokking pins and remove the locking pins from their bearing points.

• Raise the lattice extension using the chain hoist until the bore holes in the tie member can be seen below.

• Reinsert the two pins into the bearing points and secure them with the retaining pins.

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• Release the chain hoist and detach it.

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Heavy load lattice extension 6.3 Installation and rigging work

6.3.5

G

Positioning the hoist rope Risk of accidents due to falling parts!

Always secure the hoist rope holding rollers and rods with retaining pins.

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

• Remove the rope safety rollers and rods on the main boom (1) and heavy load lattice extension (2).

• Guide the rope over the sheave on the main boom head and over the head sheave on the lattice extension.

• Put all hoist rope safety rollers and rods back in place and secure these with retaining pins.

• Attach the hook tackle or the hook block. The hoist cable can be single or double reeved; Potential reeving on heavy load lattice extension, p. 6 - 18

à

• The double reeved hoist rope is attached at

à

fixing point (3); operating instructions for the truck crane – Part 2, Chapter Rigging work, Section Hoist rope / Reeving on main boom.

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6 - 17

Heavy load lattice extension 6.3 Installation and rigging work

Potential reeving on heavy load lattice extension

The hoist rope can be single or double reeved.

Hook tackle max. load capacity of the hook blocke 12 t max. load capacity with GMK 5200/6220/6220-L 9,5 t reeving: 1 fall

Single pulley hook block max. load capacity of the hook block 32 t max. load capacity with GMK 5200/6220/6220-L 19 t reeving: 1 to 2 falls

1 fall

1 fall

2 fall

à

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Reeving the hoist rope on the hook block; operating instructions for the truck crane, Part 2, Chapter Rigging work, Section – Hoist rope / reeving on main boom.

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Heavy load lattice extension 6.3 Installation and rigging work

6.3.6

Lifting limit switch on the heavy load lattice extension The functions Raise hoist, Extend main boom, Lower main boom and Lower lattice extension are monitored during operation with the heavy load lattice extension by the lifting limit switch on the lattice extension and are switched off when the lifting limit switch is actuated.

When operating with the heavy load lattice extension, there are two possibilities for lifting limit switch connections: – When using the main and auxiliary hoist, a lifting limit switch must be connected to both the main boom and the heavy load lattice extension in order to monitor the function of both hoist units.

– If using the auxiliary hoist only, the connection on the main boom is overridden.

S Overriding connection on main boom

Danger of damage to electrical connections!

Always disconnect the electrical connections to the lattice extension before slewing onto the main boom basic section.

In this way, you avoid damaging the electrical connections to the lattice extension while slewing.

For operation with the heavy load lattice extension, you must override the lifting limit switch connection on the main boom.

• Insert the short-circuit plug (1) in the socket for the connection of the lifting limit switch.

The connection is now overridden.

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6 - 19

Heavy load lattice extension 6.3 Installation and rigging work

On the heavy load lattice extension

• Place the lifting limit switch (5) in the holder (4)and secure it with a retaining pin.

• Remove the short-circuit plug (1) from the socket (3).

• Connect the lifting limit switch plug (2) to the socket (3).

Removing the heavy load lattice extension

If the lattice extension is to be folded onto the side of the main boom basic section, the lifting limit switch on the extension must be removed as follows.

• When removing, you must insert the shortcircuit plug (4) back in the sokket (5).

• Plug the connecting plug (2) into the dummy plug (1) on the cross-strut.

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• Wrap the cable around the two hooks (3).

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Heavy load lattice extension 6.3 Installation and rigging work

6.3.7

Transporting on a separate vehicle For driving on open roads with a maximum 12 t axle load, the heavy load lattice extension on the main boom must be removed and set on a separate vehicle.

G

Risk of injury!

Sling the lattice extension only on the designated slinging points and use only lifting gear with sufficient load bearing capacity.

In this way you avoid dropping the extension while loading and causing injury; Slinging points Center of gravity, p. 6 - 2

à

.

For transport, set the lattice extension down such that it will not be damaged.

• Additionally, always secure the lattice extension on the separate vehicle

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with belts to prevent slipping and overturning.

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Heavy load lattice extension 6.3 Installation and rigging work

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Heavy load lattice extension 6.4 Raising and setting down the main boom with rigged heavy load lattice extension

6.4

Raising and setting down the main boom with rigged heavy load lattice extension

G H

Risk of accidents if the chain hoist should fall off!

Always detach the chain hoist for setting working positions before operating with the heavy load lattice extension.

In this way you will avoid damaging the main boom with the chain hoist or causing injury should the hoist drop.

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

To raise and set down, the following requirements must be met: – On the SLI, the SLI code is selected for the actual rigging mode with heavy load lattice extension; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Operation of the safe load indicator – Setting the rigging mode.

à

– The current reeving of the hoist cable on the lattice extension is entered.

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– Apart from the hook block there is no load on the lattice extension.

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Heavy load lattice extension 6.4 Raising and setting down the main boom with rigged heavy load lattice extension

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Heavy load lattice extension 6.5 Operation with the heavy load lattice extension

6.5

Operation with the heavy load lattice extension

G H H

SLI-shutdown

Risk of accidents if the chain hoist should fall off!

Always detach the chain hoist for setting working positions before operating with the heavy load lattice extension.

In this way you will avoid damaging the main boom with the chain hoist or causing injury should the hoist drop.

If a heavy load lattice extension is reeved during operation with the main boom, the loads given in the Lifting capacity tables decrease. The values which have to be taken off the loads are given in the Lifting capacity tables in their own table.

The hoisting, lowering, slewing, derrick and telescoping movements are done in the same way as when operating with the main boom. Telescoping, however, is cleared by the SLI only for main boom angles below 60° or 80° (for exact value see Rigging programs in the lifting capacity table).

à

The SLI monitors operation when working with the heavy load lattice extension.

SLI shutdown can occur with heavy load lattice extension operation for the same reasons as when operating with the main boom; operating instructions for the truck crane, Part 2, Chapter Crane operation, Section Operating the safe load indicator – During crane operation – SLI shutdown.

à

Procedure if the permissible wind speed is exceeded

Strong winds can overstrain the truck crane. It is therefore important to pay close attention to the instructions in operating instructions of the truck crane, Part 2, Chapter Crane work with the main boom, Section External influences during crane operation –Wind/ Influence of wind on crane work Procedure if the permissible wind speed is exceeded while carrying out crane work with the heavy load lattice extension Wind speed less than 20 m/s

Wind speed greater than 20 m/s

• Set down the load.

• Slew the superstructure so

• Set down the load.

• Fully retract the main boom.

• Place the main boom with heavy load lattice extension in the boom support.

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that the main boom creates as little wind resistance as possible.

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Heavy load lattice extension 6.5 Operation with the heavy load lattice extension

6.5.1

S

Telescoping with rigged heavy load lattice extension The main boom may become overloaded!

While you are telescoping the main boom with the rigged heavy load lattice extension, you may not simultaneously slew the superstructure.

This prevents the main boom being subjected to additional side forces and increased vibration and becoming overloaded.

Telescoping with a load is released by the SLI only for loads which are below the values in the rigging programs.

Telescoping with a rigged heavy load lattice extension is released by the SLI if the main boom is derricked in below 60° or 80° ( Rigging program in the lifting capacity table).

If the main boom angle is too small for telescoping with the rigged lattice extension angle, the SLI displays the corresponding error message.

à

• Set down the load.

• Derrick in the main boom by the appropriate angle according to the rigging program (

à Rigging program in the lifting capacity table).

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Telescope the main boom by the required length, taking into account the hook block; lower or raise it using the hoist.

Do not actuate the slewing gear when telescoping.

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Heavy load lattice extension 6.5 Operation with the heavy load lattice extension

6.5.2

Turning loads When turning loads it is necessary to employ a two-hook operation. Twohook operation is permitted only in conjunction with a lattice extension.

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.

Two-hook operation with the heavy load lattice extension is not permitted!

Risk of accidents due to overloading!

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

Regarding position and function of necessary operating instruments; operating instructions for the truck crane, Part 2, Chapter Description of the truck crane, Section Functional description of the display and operating elements.

à

The following description requires that – the main hoist rope is reeved on the main boom and

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

G

Risk of accidents due to overloading!

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

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

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Heavy load lattice extension 6.5 Operation with the heavy load lattice extension

Setting SLI

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

H

It is advisable to enter the reevings for both hoists at the start. The values are stored and called up directly when switching hoisting gears. This 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 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.

On the indicator lamps Hoists, lamp II is flashing for the auxiliary hoist.

• In the display Reeving, enter the quantity of reeved ropes on the auxiliary

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hoist rope of the auxiliary single-sheave boom top.

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Heavy load lattice extension 6.5 Operation with the heavy load lattice extension

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

ü •

Switch the main hoist on by pressing the Main hoist shutdown rocker switch up.

On the display lamps Hoists, lamp II is now lit for the auxiliary hoist and lamp I is flashing for the main hoist.

• Set the SLI code for crane operation with the heavy load lattice extension, valid for the current rigging mode of the truck crane.

Now the SLI is set for two-hook operation; this takes into account the reeving for the auxiliary hoist and the lifting capacity table for the heavy load lattice extension.

H Turning a load

S

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

Danger of accidents due to overloading!

Acceleration forces are an additional load on the crane.

For this reason, move the load during two-hook operation at the lowest possible speed! This prevents parts of the crane (two-stage swing-away lattice extension) from being overloaded.

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

As long as the load is hanging on two hooks, you may not switch the SLI code to Operation with the main boom. It must be set to Operation with the heavy load lattice extension during the entire lifting procedure.

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H H

The load measurement is taken in two-hook operation via the pressure in the main boom’s derricking cylinder. The loads detailed in the Lifting capacity table then decrease by the weight of both reeved hook blocks.

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Heavy load lattice extension 6.5 Operation with the heavy load lattice extension

• 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.

• Now lift the load with the hook block on the main boom until both slinging

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

Turning the load is thus completed.

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points are at the same height.

7 Alphabetical Index

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Alphabetical Index

7

Alphabetical Index

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H

à

Information about the use of the index operating instructions for the truck crane, Overview chapter, section How can I quickly and surely find the information I need?

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7-1

Alphabetical Index

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Alphabetical Index

A

Auxiliary single-sheave boom top reeving options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

B

Boom extension axle loads GMK 5200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26 axle loads GMK 6220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29 axle loads GMK 6220-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 32 rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13 rigging mode GMK 5200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26 rigging mode GMK 6220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29 rigging mode GMK 6220-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 32

C

CHECK LIST installing two-stage swing-away lattice extension . . . . . . . . . . . . . 3 - 12 mounting heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 removing heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5 removing the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . 6 - 8 removing two-stage swing-away lattice extension . . . . . . . . . . . . . 3 - 14 rigging 13 m swing-away lattice extension . . . . . . . . . . . . . . . . . . . 3 - 16 rigging 22 m two-stage swing-away lattice extension . . . . . . . . . . 3 - 24 rigging 30 m/38 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 rigging the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . 6 - 6 unrigging 13 m swing-away lattice extension . . . . . . . . . . . . . . . . . 3 - 20 unrigging 22 m two-stage swing-away lattice extension . . . . . . . . 3 - 28 unrigging 30 m/38 m boom extension . . . . . . . . . . . . . . . . . . . . . . . 4 - 10

D

Doppel-Klappspitzenausleger 22 m-Doppel-Klappspitzenausleger . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 93

E

Electrical system on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 65

H

Heavy load lattice extension identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1 installation and rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11 mounting - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25 raising and setting down the main boom with . . . . . . . . . . . . . . . . 6 - 23 removing - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5 rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11 SLI deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11 transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21

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7-3

Alphabetical Index

7-4

I

Identification of heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

L

Lattice extension electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 65 lifting the deflection sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 68 lowering the deflection sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 68 SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 79 slinging points on the two-stage swing-away lattice extension . . . . 3 - 9 Lifting limit switch on heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19

M

Maintenance work on two-stage swing-away lattice extension . . . . . . . . . . . . . . . . . . 3 - 109 Malfunctions on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 102 Malfunctions on luffing jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 101 two-stage swing-way lattice extension . . . . . . . . . . . . . . . . . . . . . . 3 - 101

P

Pin connections for heavy load lattice extension operation . . . . . . . . . . . . . . . . . . . . 6 - 13

R

Reeving on heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18 Reeving hoist rope on heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17 Reeving methods on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 71

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Operating instructions lattice extension GMK 5200/6220/6220-L

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transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11 working positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14 Hoist rope possible reeving methods on the lattice extension . . . . . . . . . . . . . 3 - 71 reeving on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 70 Hoist rope, potential reeving on heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18

Alphabetical Index

Reeving options on the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . 5 - 7 Reeving the hoist rope at the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23 Rigging mode when rigging/unrigging the lattice extension . . . . . . . . . . 3 - 33, 4 - 13 Rigging work boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13 heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11

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SLI deactivation, operation with the lattice extension . . . . . . . . . . . . . . 5 - 11 malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 102 shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25 shutdown when working with the lattice extension . . . . . . . . . . . . 3 - 79 Symbols in the operating instructions, explanation . . . . . . . . . . . . . . . . 1 - 2

Telescopic swing-away lattice extension turning loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 81 Transport heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21 Transport condition of the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35 Turning loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12 with the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 6 - 27 Two-hook operation turning loads with the heavy load lattice extension . . . . . . . . . . . . 6 - 27 Two-stage swing-away lattice extension axle loads GMK 5200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 88 axle loads GMK 6220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 91 axle loads GMK 6220-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 94 lubricant chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 107 maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 105 maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 109 operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 operating elements in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33 rigging mode GMK 5200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 88 rigging mode GMK 6220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 91 rigging mode GMK 6220-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 94

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Operating instructions lattice extension GMK 5200/6220/6220-L

3 112 208 en

7-5

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Alphabetical Index

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3 112 208 en

Operating instructions lattice extension GMK 5200/6220/6220-L