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

12. Remove locking pins between 9 m (30 ft) section and 12.5 m (41 ft) section on the left side and remove the lower pin on the right side with the head (left 2 pins, right 1 pin); à Connections on lattice extension, p.3-55. à Relieving the load on bearing points, p.3-53.

13. Raise lattice extension and swing 9 m (30 ft) section at the side onto the 12.5 m (41 ft) section; à Swinging the 9 m (30 ft) section in front of the 12.5m (41ft) section, p.3-62.

14. Establish connection between 9 m (30 ft) and 12.5 m (41 ft) sections; à Connections in the middle area , p.3-46.

15.If the 9 m (30 ft) section needs to be removed, attach 9 m (30 ft) section on auxiliary crane, remove all locking pins between 9 m (30 ft) section and 12.5 m (41 ft) section and place 9 m (30 ft) 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 (41 ft) section and remove the locking pin between the 12.5 m (41 ft) section and the main boom head on the left side of the main boom; à Connections on the main boom head, p.3-53. à Relieving the load on bearing points, p.3-53.

18. Remove locking pin between 12.5 m (41 ft) section and main boom head on the right side of the main boom; à Connections on the main boom head, p.3-53.

19. Attach the guide rope to the head of the 12.5 m (41 ft) section and raise the lattice extension completely.

20. Swinging 12.5 m (41 ft) section onto the main boom; à Swinging the lattice extension when rigging, p.3-61.

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

22. Remove the swinging connection between the 12.5 m (41 ft) section and the main boom head; à Connections on main boom head, p.3-48.

23. Swing the 12.5 m (41 ft) section on the run-up rail onto the main boom; à Swinging the lattice extension onto the main boom head , p.3-64.

HIf the 9 m (30 ft) section has been removed, see Point 25.

24. Establish connection between 9 m (30 ft) section and main boom; à Connections in the rear area, p.3-47.

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

25. If the 9 m (30 ft) section has been removed, lock the 12.5 m (41 ft) section on the run-up rail; àConnections in the middle area, p. 3-46.

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

27. Disconnect electrical connection between 12.5 m (41 ft) section and main boom; à 13 m (43 ft) swing-away lattice extension , p.3-65.

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

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

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.

–The main boom is completely retracted (0/0/0/0/0) and has been lowered into horizontal position.

–If the truck crane is equipped with two hoists with additional equipment, the hook block is unreeved on the hoist which is not used for working with the lattice extension.

Requirements for unrigging

Before you lower a two-stage swing-away lattice extension into a horizontal position, the following requirements must be met:

–No other load is raised outside the hook block.

–The required counterweight version for operation with the rigged lattice extension according to the Lifting capacity table is rigged.

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

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

–The lattice extension is raised completely.

–The SLI code is entered for operation with the rigged lattice extension.

If these requirements are met, lowering into the horizontal position with lattice extension/boom extension and a slewing range of 360° is permitted and is monitored by the SLI; à Raising the setting down the main boom with rigged lattice extension, p.3-77.

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

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

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3.6.2 Checking the transport condition

For transportation you must establish certain connections between both parts of the lattice extension. The connections which need to be established depend on whether the lattice extension:

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

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

SBe 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.

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 (30 ft) section and 12.5 m (41 ft) section are folded at the side:

–The 12.5 m (41 ft) section is raised into the holder on the main boom with the retaining mandrel (1); à Lowering/raising retaining mandrel on main boom, p.3-57.

–The 12.5 m (41 ft) section is secured with the locking pin (8); à Locking pin for 12.5 m (41 ft) section , p.3-58.

–The connection is made (2) between the 9 m (30 ft) section and the 12.5 m (41 ft) section; à Connections in the front area, p.3-44.

–The connections (3) and (4) are made on the pivot point between the 9m (30 ft) section and the 12.5 m (41 ft) section; à Connections on lattice extension, p.3-50.

If only the 12.5 m (41 ft) section is folded at the side:

–The 12.5 m (41 ft) section is raised into the holder on the main boom with the retaining mandrel (1); à Lowering/raising retaining mandrel on main boom, p.3-57.

–The 12.5 m (41 ft) section is secured with the locking pin (8); à Locking pin for 12.5 m (41 ft) section , p.3-58.

–The connection (6) is made between the 12.5 m (41 ft) section and the runup rail; àConnections in the middle area, p. 3-46.

If only the 9 m (30 ft) section is folded at the side:

–The connection (5) is made between the 9 m (30 ft) section and the main boom; à Connections in the rear area, p.3-47.

–The connection (7) is made between the 9 m (30 ft) section and the main boom; à Connections in the front area, p.3-44.

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 (30 ft) section and the 12.5 m (41 ft) section; à Connections on lattice extension, p.3-50.

–The connection (4) is made between the 9 m (30 ft) section and the 12.5 m (41 ft) section; à Connections in the front area, p.3-44.

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; à GMK 5200/6220-L operating instructions, Part 1, Chapter Driving with the truck crane, Section Checking the truck crane before driving – Driving mode table .

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; à Locking device for transportation, p.3-38.

–Installation of the hose drum; à Installing hose drum, p.3-39.

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

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

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.

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.

SRisk 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).

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

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.

GRisk 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.

Establishing hydraulic connection

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

HThe connections are made via quick-action couplings. Half couplings belonging together are colour coded. Use the delivered levering tool to make the hydraulic connections; à Connecting quick couplings with levering tool, p.4-17.

• 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).

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; à p.3-38.

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.

• Put the protective caps in place.

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.

GRisk 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.