Auxiliary single-sheave boom top 5.1

SDanger 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.

HFor 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.

SDanger 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 your local GROVE Customer Service!

The serial number can be found on the front (1) of the auxiliary single-sheave boom top.

Blank Page

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; à Installing the auxiliary single-sheave boom top, p.5-5.

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).

• 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-tobracket-switch has been wound onto the hook and the plug is in the dummy case.

All pins need to be secured with locking pins.

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.

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

SRisk 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.

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 anchor-to-bracket-switch; à Connecting the anchor-to-bracket-switch, p.5-9.

All pins need to be secured with locking pins.

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 tackle12 t (26 500 lbs) max. lifting capacity of the GMK 5200/6220-L 9,5 t (20 900 lbs)

Reeving: 1 times on the auxiliary single-sheave boom top

1-Rollen-Hakenflasche max. lifting capacity of the hook tackle32 t (70 500 lbs) max. lifting capacity of the GMK 5200/6220-L 9,5 t (20 900 lbs)

Reeving: 1 times on the auxiliary single-sheave boom top

Auxiliary single-sheave boom top 5.4 Reeving the hoist cable

Blank Page

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.

• 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-tobracket-switch of the main hoist with the socket on the left side of the main boom head; à GMK 5200/6220-L operating instructions, 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.

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).

Auxiliary single-sheave boom top

5.5 Connecting the anchor-to-bracket-switch and anemometer

Connecting the anemometer

• Connect the anemometer as described in the supplied à Operating instructions GMK5200/6220-L, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Anemometer.

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; à Auxiliary singlesheave boom top, p.2-1 and p.2-3.

HHoisting, 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 à Installation graphs in the lifting capacity table).

SLI deactivation

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; à Operating instructions. What

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 à Operating instructions GMK5200/6220-L, 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 (66ft)/s Wind speed above 20 m (66 ft)/s

• Lower load to the ground.

• Rotate the superstructure so that the main boom is exposed to as little wind as possible.

• Lower load to the ground.

• Retract main boom completely.

• Rest main boom with auxiliary singlesheave boom top in the boom support.

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.

GRisk 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!

GRisk of accidents due to overloading!

The load must always be raised completely starting with the weakest part (auxiliary single-sheave boom top).

HRegarding position and function of necessary operating instruments; à Operating instructions GMK5200/6220-L operating instructions, Part 2, Chapter Description of the truck crane – crane section , Section Functional description of the display and operating instruments

Prerequisites 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.

GRisk 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.

Auxiliary single-sheave boom top 5.6 Operation with the auxiliary single-sheave boom top

Setting the SLI For the two-hook operation both hoists on the SLI need to be switched on.

HIt 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:

C• 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.

4 4

• 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 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. s

Auxiliary single-sheave boom top

5.6 Operation with the auxiliary single-sheave boom top

• 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.

HLoad 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.

Turning the load For turning the load, proceed as follows.

SDanger 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.

HAs 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.

HAs 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.

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 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.

Auxiliary single-sheave boom top

5.6 Operation with the auxiliary single-sheave boom top

Blank Page

6Heavy load lattice extension

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.

Danger of malfunction and damage!

SOperate 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.

H

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.

SDanger 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 GROVE Customer Support at the respective location!

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 Center of gravity

GIn 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 à p.2-2 and p.2-4

• Tie down the lattice extension in the 0° position such that it hangs horizontally level to the auxiliary crane.

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 (26500lbs) axle load; à CHECKLIST: Mounting heavy load lattice extension, p.6-4,

–folded down on the side of the main boom; à CHECKLIST: Rigging the heavy load lattice extension, p.6-6,

–supposed to be folded onto the main boom; à CHECKLIST: Removing the heavy load lattice extension, p.6-8or

–supposed to be removed for on-road driving with a maximum 12 t (26500lbs) axle load; à CHECKLIST: Removing heavy load lattice extension, p.6-5.

6.2 Checklists for rigging work on the heavy load lattice extension

6.2.2 CHECKLIST: Mounting heavy load lattice extension

HThis 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 at0°.

–An auxiliary crane is available.

1. Sling the heavy load lattice extension onto the auxiliary crane; à Center of gravity, p.6-2.

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; à Swiveling lattice extension in front of main boom head , p.6-12.

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 extension and the boom; à Heavy load lattice extension in transport position, p.6-11.

6.2 Checklists for rigging work on the heavy load lattice extension

6.2.3 CHECKLIST: Removing heavy load lattice extension

HThis 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 at0°.

–An auxiliary crane is available.

1. Sling the heavy load lattice extension onto the auxiliary crane; à Center of gravity, p.6-2.

2. Remove locking pins on both sides; à Pin connections for operating the heavy load lattice extension, p.6-13.

3. Set heavy load lattice extension on a separate vehicle; à Transporting on a separate vehicle, p.6-20.

6.2 Checklists for rigging work on the heavy load lattice extension

6.2.4 CHECKLIST: Rigging the heavy load lattice extension

HThis 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; à p.6-11.

3. Swivel the lattice extension in front of the main boom head; à Swiveling lattice extension in front of main boom head , p.6-12.

4. Lock the lattice extension to the right and left side of the main boom; à Pin connections for operating the heavy load lattice extension, p.6-13.

Heavy load lattice extension 6.2 Checklists for rigging work on the heavy load lattice extension

5. Move the lifting limit switch to the head of the lattice extension and connect it there; à Lifting limit switch on the heavy load lattice extension, p.6-18.

GMK

6. Move the heavy load lattice extension into the working position; à Working positions for the heavy load lattice extension, p.6-14.

7. Lay the auxiliary hoist rope over the sheave of the main boom and lattice extension; à Positioning the hoist rope , p.6-16.

8. Reeve the hoist rope on the hook block; à Operating instructions

GMK5200/6220-L – Hoist rope/reeving on main boom.

9. Attach lifting limit switch weight and guide hoist rope through the weight; à Operating instructions GMK5200/6220-L – Lifting limit switch weight.

10. Install the anemometer on the main boom; à Operating instructions

GMK5200/6220-L – Anemometer.

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; à Operating instructions GMK5200/6220-L– Rigging mode

Further working steps for raising the boom; à p.6-21. Telescoping with rigged heavy load lattice extension; à p.6-24.

6.2 Checklists for rigging work on the heavy load lattice extension

6.2.5 CHECKLIST: Removing the heavy load lattice extension

HThis 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; à Removing the heavy load lattice extension, p.6-19,à Operating instructions GMK5200/6220-L – Lifting limit switch weight.

3. Unreeve the hoist rope from the hook block and roll it onto a drum; à Operating instructions GMK5200/6220-L, Part 2, Chapter Rigging work, Section Rigging work on the main boom – Reeving and unreeving the hoist rope.

4. Heavy load lattice extension in 0° position; à Moving the heavy load lattice extension into the 0° position, p.6-15.

5. Fasten the guide rope onto the head of the 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; à Pin connections for operating the heavy load lattice extension, p.6-13.

HIf the heavy load lattice extension is to be removed for on-road driving, continue with CHECKLIST: Removing the heavy load lattice extension, à p.6-5

7. Slew the heavy load lattice extension onto the main boom.

8. Insert and secure locking pins at the bearing points between the lattice extension and the main boom basic section; à Heavy load lattice extension in transport position, p.6-11.

Heavy load lattice extension

6.2 Checklists for rigging work on the heavy load lattice extension

Blank Page

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.

Risk of accidents due to falling parts!

GAlways 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.

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; à p.6-11.

–The locking pin between the lattice extension and basic main boom section is inserted and secured.

HWhen 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

GRisk 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 basic section.

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

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.

Risk of accidents due to falling parts!

GAlways 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. The pins can remain at the bearing points during operation.

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)

– 25° position

Moving the heavy load lattice extension into the 25° position

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 locking 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; à p.6-16.

Moving the heavy load lattice extension into the 0° position

• 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 locking 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.

• Release the chain hoist and detach it.

6.3.5 Positioning the hoist rope

Risk of accidents due to falling parts!

GAlways 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; à Potential reeving on heavy load lattice extension, p.6-17

• The double reeved hoist rope is attached at fixing point (3); à Operating instructions

GMK5200/6220-L – Part 2, Chapter Rigging work, Section Hoist rope / Reeving on main boom.

Potential reeving on heavy load lattice extension

6.3 Installation and rigging

The hoist rope can be single or double reeved.

Hook tackle max. load capacity of the hook blocke12 t (26 600 lbs) max. load capacity with GMK 5200/6220-L 9,5 t (20 900 lbs) reeving: 1 fall

Single pulley hook block max. load capacity of the hook block32 t (70 500 lbs) max. load capacity with GMK 5200/6220-L 19 t (41 850 lbs) reeving: 1 to 2 falls

Reeving the hoist rope on the hook block; à Operating instructions

GMK5200/6220-L, Part 2, Chapter Rigging work , Section – Hoist rope/ reeving on main boom

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.

Danger of damage to electrical connections!

SAlways 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.

Overriding connection on main boom

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.

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.

• Wrap the cable around the two hooks (3).

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.

Risk of injury!

GSling 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 à Center of gravity, p.6-2.

For transport, set the lattice extension down such that it will not be damaged.

• Additionally, always secure the lattice extension on the separate vehicle with belts to prevent slipping and overturning.

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

Risk of accidents if the chain hoist should fall off!

GAlways 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.

HTo 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; à Operating instructions GMK5200/6220-L, Part 2, Chapter Crane operation, Section Operation of the safe load indicator – Setting the rigging mode.

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

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

Heavy load lattice extension

6.4 Raising and setting down the main boom with rigged heavy load lattice extension

Blank Page

6.5 Operation with the heavy load lattice extension

6.5 Operation with the heavy load lattice extension

GRisk 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.

HIf 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.

HThe 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 à Rigging programs in the lifting capacity table ).

SLI-shutdown 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; à Operating instructions GMK5200/6220-L, Part 2, Chapter Crane operation, Section Operating the safe load indicator – During crane operation – SLI shutdown.

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 à Operating instructions GMK5200/ 6220-L, 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 (66 ft)/s

• Set down the load.

• Slew the superstructure so that the main boom creates as little wind resistance as possible.

Wind speed greater than 20 m (66 ft)/s

• Set down the load.

• Fully retract the main boom.

• Place the main boom with heavy load lattice extension in the boom support.

6.5 Operation with the heavy load lattice extension

6.5.1 Telescoping with rigged heavy load lattice extension

SThe 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° (à 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.

• 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).

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.

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.

Risk of accidents due to overloading!

GLifting 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!

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

HRegarding position and function of necessary operating instruments; à GMK 5200/6220-L operating instructions, Part 2, Chapter Description of the truck crane, Section Functional description of the display and operating elements.

Prerequisites

The following description requires that –the main hoist rope is reeved on the main boom and –the auxiliary hoist rope on the heavy load lattice extension is reeved.

Risk of accidents due to overloading!

GThe 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.

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.

HIt 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 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.

4 4

• 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.

C• Switch off both hoists.

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

C• 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 hoist rope of the auxiliary single-sheave boom top.

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.

• 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

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.

Turning a load

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

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. H

As long as the load is hanging on two hooks, you may not switch the SLI code to Operation with the main boom. It must be set to Operation with the heavy load lattice extension during the entire lifting procedure.

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 points are at the same height.

• 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.

HInformation about the use of the index à Operating instructions GMK5200/6220-L, Overview chapter, section How can I quickly and surely find the information I need?

C Check List

extension