Grove Crane GMK 6400 Boom Extension light Operating Instruction Manual 3113164 - PDF DOWNLOAD

Operating instructions Boom extension, light

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Important note Any kind of duplication or excerpt from this document, even in electronic form, is not subject to updating by Manitowoc Crane Group Germany GmbH.

© Copyright reserved by

Industriegelände West D-26389 Wilhelmshaven, Germany Tel.: [+49] (0) 44 21 294-0 Fax: [+49] (0) 44 21 294-301 The passing on or duplication of this document as well as the utilisation and disclosure of its contents is prohibited unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility model are reserved. The original language of this document is German.

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Operating instructions Boom extension, light GMK 6400

10.12.2014

Manitowoc Crane Group Germany GmbH

These operating instructions consist of the following chapters:

1 Overview 2 Basic safety instructions 3 For operations planning 4 Additional operating and display elements 5 Boom extension, light 6 Driving with a rigged truck crane 7 Malfunctions 8 Maintenance

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9 Index

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Operating instructions Boom extension, light GMK 6400

1 Overview

1.1

Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

1

1.2

Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

1

1.3

Terms used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

2

1.3.1 1.3.2

For the boom extension, light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 On the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

2 4

1.4

Notes on the lattice extension operating manual . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

5

1.4.1 1.4.2 1.4.3 1.4.4

What do the symbols used mean? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Definition of direction information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 How are the operating instructions structured?. . . . . . . . . . . . . . . . . . . . . . . . . . 1 How do I find the information I need? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

5 5 7 8

1.5

Conversion table for US measuring units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

9

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1

Operating instructions Boom extension, light GMK 6400

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Operating instructions Boom extension, light GMK 6400

Overview 1.1 Accidents

1

Overview

1.1

Accidents In case of an accident, contact the branch in the country in which you are GMK 6400 operating instructions the secworking; Manitowoc Crane Care; tions Accidents and Branches.

à

Adhere to the requirements regarding the obligation to report accidents prevalent in the country in which you are working and inform the supervisory authorities responsible for that particular type of accident (e.g. material damage, injuries to persons).

1.2

Warranty

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You will find information about the warranty in the GMK 6400 operating instructions in the section Information about the warranty.

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1-1

Overview 1.3 Terms used

Terms used

1.3.1

For the boom extension, light

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1.3

The possible combinations of the boom extension;

1-2

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à p. 3 - 4

Operating instructions Boom extension, light GMK 6400

Overview 1.3 Terms used

Adapter 1 – Button unit connection 2 – Deflection sheave 3 – Hydraulic locking pin 4 – Bracing arms Intermediate sections 5 – Short intermediate section with a small cross-section 6 – Long intermediate section with a small cross-section Angle piece 7 – Deflection sheave 8 – Lattice extension Head 9 – Head sheaves 10 – Terminal box 11 – Deflection sheave 12 – Clamp for anemometer 13 – Cable drum 14 – Fixed point for the hoist rope

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15 – Clamp for lifting limit switch

Operating instructions Boom extension, light GMK 6400

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1-3

Overview 1.3 Terms used

1.3.2

On the main boom

1 – Hydraulic locking pin connections

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2 – Electrical connection control

1-4

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Operating instructions Boom extension, light GMK 6400

Overview 1.4 Notes on the lattice extension operating manual

1.4

Notes on the lattice extension operating manual

1.4.1

What do the symbols used mean?

The signs and symbols used in this operating manual for especially important information can be found in the GMK 6400 operating instructions in the section Notes on the operating manual.

1.4.2

Definition of direction information

Basic rule

Direction information always depends on whether the carrier or the superstructure is being operated.

On the carrier The driver's cab is always at the front, which means that: 1: front

2: right

3: rear

4: left

Reverse always means with driver's cab leading, Backwards always means the rear lights on the carrier are leading.

On the superstructure The main boom head is always at the front, which means that: 1: front

2: right

3: rear

4: left

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s

Operating instructions Boom extension, light GMK 6400

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1-5

Overview 1.4 Notes on the lattice extension operating manual

Switches and buttons

For switches and buttons, the terms down and up are used.

Regardless of the fitting position (vertical, horizontal, diagonal, perpendicular or turned), the following always applies: Down: if (1) press – next to the symbol Up:

General notes on the operating elements

if (2) press – opposite the symbol

Some switches are provided with a lock button.

The lock button (1) will not be mentioned again during operation. The following applies to all switches with a lock button: – Switching on:

– First press the lock button – then press the lower switch down

– To switch off:

Information for display on buttons and symbols on the display GMK 6400 operating instructions section General rules for buttons and symbols.

à

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General rules for buttons and symbols

Press upper switch down until the lock button latches into place

1-6

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Operating instructions Boom extension, light GMK 6400

Overview 1.4 Notes on the lattice extension operating manual

1.4.3

How are the operating instructions structured?

Chapter 1 contains an overview of the lattice extensions, among other points.

Chapter 2 contains information on the safety requirements.

In chapter 3 you will find specifications for operation planning, such as dimensions, weight, identification and centre of gravity position of the lattice extension.

Chapter 4 shows the overview and gives a brief description of the display and operating elements for the lattice extension.

In chapter 5, rigging and operation of lattice extensions is described.

In chapter 6 you will find information on how to drive a rigged crane on construction sites.

Instructions for troubleshooting in the event of a malfunction are specified in chapter 7.

Chapter 8 describes the maintenance of lattice extensions.

Chapter 9 contains the index.

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G

Risk of accidents when only referring to the checklists during operation The checklists and operating instructions should always be regarded as a single unit for the comprehensive description of the rigging.

It is only safe to operate the truck crane by referring to the checklists when you are familiar with all the dangers which may occur, and are confident in completing the necessary steps as described in the relevant operating instructions.

If in doubt, always first read the section which is referred to in the checklist.

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1-7

Overview 1.4 Notes on the lattice extension operating manual

1.4.4

How do I find the information I need?

The operating instructions contain the following guides for orientation.

– The Table of contents contains a list of all chapters.

– The Table of contents ahead of each chapter provides an overview of the topics it contains.

– The Index in chapter 9 provides an alphabetic list of keywords and search terms with a reference to the relevant page in the lattice extension operating manual.

à

– Cross-references are labelled with an arrow ( ) and refer to other pages in the operating instructions. These pages contain more detailed information, or information that relates to the topic in question.

Furthermore, you can use the cross-references to systematically familiarize yourself with general to specific information on the truck crane or look up the functioning of individual elements.

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You will find an example of the use of cross references in the GMK 6400 operating instructions.

1-8

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Operating instructions Boom extension, light GMK 6400

Overview 1.5 Conversion table for US measuring units

1.5

Conversion table for US measuring units The following conversion factors will help you convert from metric to US units when the truck crane is used in countries that use US units of measurement and vice versa. into

Multiply by

mm

in

0.03937

in

mm

25.4

m

ft.

3.28084

ft

m

0.30479

m²

ft²

10.76391

cm²

in²

0.155

cm³

in³

0.061

l

gal (US)

0.264178

kg

lbs

2.204622

lbs

kg

0.45359

t

lbs

2204.622

lbs

t

0.0004536

kN

lbf

224.809

daN/cm²

lbf/in²

14.50378

lbf/in²

daN/cm²

0.06895

bar

psi

14.50378

psi

bar

0.06895

m/s

ft/s

3.28084

km/h or km

mph or mi

0.62137

mph or mi

km/h or km

1.60935

Nm

lbf ft

0.7375

°C

°F

1.8 x °C + 32

°F

°C

(°F-32)/1.8

t/m²

lbs/ft²

204.8

m²/t

ft²/lbs

0.04882

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Converting from

Operating instructions Boom extension, light GMK 6400

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1-9

Overview 1.5 Conversion table for US measuring units

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Blank page

1 - 10

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Operating instructions Boom extension, light GMK 6400

2 Basic safety instructions

2.1

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1

2.2

Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

2

2.3

Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

2

2.4

Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

3

2.5

Safety instructions for working with the lattice extension. . . . . . . . . . . . . . . . . . 2 -

4

2.6

Notes on transporting persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

5

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2

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Operating instructions Boom extension, light GMK 6400

Basic safety instructions 2.1 Intended use

2

Basic safety instructions In principle, the basic safety instructions from the GMK 6400 operating instructions apply. The basic safety instructions for the lattice extensions supplied for the truck crane are given below.

H 2.1

Information regarding the warnings and symbols used; à GMK 6400 operating instructions.

Intended use The GMK 6400 is a state-of-the-art truck crane, designed in accordance with approved safety regulations. Nevertheless, the operator or third parties can still be endangered and the crane or other property put at risk while using it.

H

In addition to the following specifications, also follow the specifications about proper use given in the GMK 6400 operating instructions.

The GMK 6400 may only be operated with parts of equipment which are permitted by Manitowoc Crane Group Germany GmbH and which are labelled with the serial number of the GMK 6400.

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Observe the inspection and maintenance requirements for the lattice extension according to the Maintenance chapter.

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2-1

Basic safety instructions 2.2 Improper use

2.2

Improper use Manitowoc Crane Group Germany GmbH is not liable for damage resulting

from improper or unauthorized use of the GMK 6400 truck crane. The user alone bears the risk.

H

In addition to the following specifications, also follow the specifications about proper use given in the GMK 6400 operating instructions.

When rigging the light boom extension, do not use the rigging winch.

If a rigging winch (additional equipment) is mounted, improper use also includes: – Pulling the main hoist rope using the rigging winch (additional equipment) to the main boom head when no lattice extension is mounted – Any type of vertical hoisting of loads using the rigging winch.

2.3

Organisational measures

H

In addition to the following specifications, also follow the organizational measures specified in the GMK 6400 operating instructions and in the Maintenance manual.

Make sure the maintenance personnel also have the necessary expertise to operate the crane safely. Make sure the maintenance personnel have access to the operating manual.

Only qualified or trained personnel may carry out work on the truck crane.

Responsibilities regarding the operation of the crane, rigging, maintenance and repair work must be clearly defined.

Make sure that persons who will work on the truck crane are provided with the required information prior to starting operations. Instruct your personnel (e.g. banksmen, slingers, rigging personnel) accordingly.

Observe all safety instructions and warnings on the truck crane.

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Climb on the foot section only via the ladder provided. Erect the railing.

This gives you a safe access to the foot section.

2-2

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Operating instructions Boom extension, light GMK 6400

Basic safety instructions 2.4 Personnel qualifications

Welding work on load-bearing parts may only be carried out by qualified personnel with the manufacturer's prior permission. To avoid any damage, especially to electronic components, you must take certain precautions before performing any welding work. You should therefore always consult Manitowoc Crane Care before any welding work.

Spare parts must fulfil the technical requirements defined by the manufacturer. Genuine spare parts always meet these requirements.

2.4

Personnel qualifications

Requirements

These operating instructions are not a training manual for beginners.

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

Personnel in training may only operate the truck crane under supervision.

Only reliable personnel may operate or carry out work on the truck crane.

The prerequisites which you, as crane operator, must fulfil are described in the GMK 6400 operating instructions and in the Safety manual.

Only experienced personnel who are familiar with the valid accident prevention regulations are authorised to sling loads and instruct the crane operator.

Only trained personnel may be used to maintain the truck crane.

Manitowoc Crane Group Germany GmbH conducts general and type-specific crane operator courses and technical courses; GMK 6400 operating instructions Training information section.

à

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Training courses

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2-3

Basic safety instructions 2.5 Safety instructions for working with the lattice extension

2.5

Safety instructions for working with the lattice extension The operation of GMK 6400 with one of the lattice extensions described in this operating manual is subject to: – All the safety instructions contained in the operating manual supplied with the GMK 6400 and – All the following safety instructions.

Use the appropriate access aids when carrying out overhead rigging or maintenance work. Do not use parts of the crane as access aids.

Walk only on those machine parts which are equipped with appropriate tread grids and railings and therefore guarantee safety.

Always use a ladder for work above head height.

If there is a risk of falling when doing work on the truck crane, suitable equipment must be used to prevent this (e.g. ladder, lifting platform, auxiliary crane).

If the risk of falling cannot be minimised despite using such equipment, you must protect yourself and any assisting personnel by using fall arrest systems.

The points, at which the fall arrest system can be attached to on the truck crane, are indicated by the symbol shown here.

Make sure that there are no unauthorized people in the vicinity of or on the truck crane when rigging or during crane work. Cordon off the danger area clearly and mark the area as such.

Only use parts of equipment (counterweight sections, sections of the lattice extension) that belong to your truck crane. Both the truck crane and the equipment must have the same serial number.

Lifting loads simultaneously with two cranes is particularly dangerous.

Carry out this type of work with special care.

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Secure the truck crane against unauthorized use whenever you leave it.

2-4

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Operating instructions Boom extension, light GMK 6400

Basic safety instructions 2.6 Notes on transporting persons

Crane work carried out in the vicinity of live electrical cables as well as oil, gas or other supply lines is dangerous and requires that special precautionary measures be taken. Please observe the instructions in the section titled Crane operation under special operating conditions in the Safety manual and the respective national regulations.

Always secure the pins both in the connecting points and in the holders using retaining pins. This prevents unsecured pins from coming loose, falling out and causing injuries.

Observe the centre of gravity information when slinging and use suitable slinging material.

In this way, you prevent the attached sections from slipping out, falling and causing injury during installation or removal.

2.6

Notes on transporting persons

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Make sure that you follow the instructions for transporting persons in the GMK 6400 operating instructions.

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2-5

Basic safety instructions 2.6 Notes on transporting persons

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2-6

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Operating instructions Boom extension, light GMK 6400

3 For operations planning

3.1

Information on the load capacity charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

1

3.2

Notes on assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

2

3.3

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

4

3.3.1 3.3.2

Combinations Type A and Type B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Combinations Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

4 6

3.4

Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

8

3.5

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10

3.6

Slinging points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12

3.7

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

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3

Operating instructions Boom extension, light GMK 6400

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Operating instructions Boom extension, light GMK 6400

For operations planning 3.1 Information on the load capacity charts

3

For operations planning

3.1

Information on the load capacity charts In the load capacity charts, the boom extension, light, defined by length and inclination; e.g. 2.3 + 11 m 42° – Length of the boom extension 2.3 + 11 m – Inclination of the boom extension 42° The length indicates: – The length of the fixed part (3); in the example 2.3 m – The length of the inclinable part (4); in the example 11 m

The inclination is obtained from: – The fixed angle of the adapter (2) with 20° – The angle of the angle piece (1) with 0° or 22°.

From this we have 3 types of the boom extension, light: A

Type A

à p. 3 - 4

e.g. 2.3 + 11 m 20°

Angle on the adapter 20° Angle on the angle piece 0° B

Type B

à p. 3 - 4

e.g. 2.3 + 11 m 42°

Angle on the adapter 20° Angle on the angle piece 22° C

Type C

à p. 3 - 6

e.g. 8.3 + 5 m 42°

Angle on the adapter 20° Angle on the angle piece 22°

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The type is specified in the footer of the load capacity chart.

Operating instructions Boom extension, light GMK 6400

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3-1

For operations planning 3.2 Notes on assembly

3.2

Notes on assembly The boom extension, light is assembled from the same parts as the boom extenstion, the luffing jib and the heavy load lattice extension.

S

Risk of overturning Assemble the lattice extension only in the following combinations shown.

Other combinations are not permitted. Other combinations are not monitored by the RCL.

à Lattice extension operating manual.

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Assembly of the boom extension;

3-2

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Operating instructions Boom extension, light GMK 6400

For operations planning 3.2 Notes on assembly

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Operating instructions Boom extension, light GMK 6400

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3-3

For operations planning 3.3 Assembly

3.3

Assembly

3.3.1

Combinations Type A and Type B The combinations, Type A and Type B are differentiated by the angle of inclination 20° or 42°.

Please observe the section Notes on assembly, p. 3 - 2.

– Combination Type C p. 3 - 6

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à

3-4

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Operating instructions Boom extension, light GMK 6400

For operations planning 3.3 Assembly

The following tables and the adjacent diagrams show which sections are required for the different boom extensions.

2.3 + 35

2.3 + 41

2.3 + 29

2.3 + 23

2.3 + 11

Length in m

2.3 + 17

Assembly of the boom extension

(A)

(B)

(C)

(D)

(E)

(F)

20 or 422)

Inclination in ° Designation1) 9

Adapter

✔

✔

✔

✔

✔

✔

6

Number of short intermediate sections, small

1

–

1

2

1

2

5

Angle piece2)

✔

✔

✔

✔

✔

✔

7

Number of long intermediate sections, small

–

1

1

1

2

2

8

Head

✔

✔

✔

✔

✔

✔

Sections

1)

à adjacent diagram

2)

Inclinations of 0° or 22° are set on the angle piece

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Item no.1)

Operating instructions Boom extension, light GMK 6400

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3-5

For operations planning 3.3 Assembly

3.3.2

Combinations Type C Please observe the section Notes on assembly, p. 3 - 2.

à p. 3 - 4

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– Combinations Type A and Type B

3-6

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Operating instructions Boom extension, light GMK 6400

For operations planning 3.3 Assembly

The following tables and the adjacent diagrams show which sections are required for the different boom extensions.

26.3 + 5

32.3 + 5

38.3 + 5

20.3 + 5

(A)

(B)

(C)

(D)

(E)

(F)

8.3 + 5

Length in m

14.3 + 5

Assembly of the boom extension

Inclination in °

42 °

Designation1) 9

Adapter

✔

✔

✔

✔

✔

✔

6

Number of short intermediate sections, small

1

–

1

2

1

2

5

Angle piece2)

✔

✔

✔

✔

✔

✔

7

Number of long intermediate sections, small

–

1

1

1

2

2

8

Head

✔

✔

✔

✔

✔

✔

Sections

1)

à adjacent diagram

2)

An inclination of 22° is set on the angle piece

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Item no.1)

Operating instructions Boom extension, light GMK 6400

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3-7

For operations planning 3.4 Transport dimensions and weights

3.4

Transport dimensions and weights

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Take note of the data on the weight and dimensions. Use only authorised sling gear with sufficient lifting capacity.

3-8

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Operating instructions Boom extension, light GMK 6400

For operations planning 3.4 Transport dimensions and weights

Dimensions and weight of the lattice extension sections Item no.

Part

Length x width x height in m

Weight in kg

Angle piece

3.65 x 1.70 x 1.80

1 450

5.1

Deflection sheave of the angle piece

0.85 x 0.6 x 0.4

52

6

Short intermediate sections, small (without rear pendant link)

6.15 x 1.65 x 1.50

730

7

Long intermediate sections, small (without rear pendant link)

12.15 x 1.65 x 1.50

1 350

8

Head

3.50 x 1.65 x 2.00

900

9

Heavy load lattice extension adapter

1.35 x 3.80 x 2.20

1 200

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Operating instructions Boom extension, light GMK 6400

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3-9

For operations planning 3.5 Identification

3.5

Identification

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S

Risk of accidents if not adjusted correctly The lattice extension is designed for the truck crane with which it was delivered.

If a lattice extension is to be used on several truck cranes, it must be designed for that truck crane and marked with the serial number.

Have adjustments to the lattice extension carried out by Manitowoc Crane Care only.

This prevents malfunctions and damage.

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Operating instructions Boom extension, light GMK 6400

For operations planning 3.5 Identification

Identification of the lattice extension sections Item no.

Part

The serial number (A) is ...

Angle piece

... on the right at the rear of the upper strut.

6, 7

All intermediate sections

... on the right at the rear on the grille frames.

8

Head

... on the right at the rear of the upper strut.

9

Heavy load lattice extension adapter

... above rear right.

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Operating instructions Boom extension, light GMK 6400

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3 - 11

For operations planning 3.6 Slinging points

3.6

Slinging points

G

Danger of accidents if used improperly Only fit slings to the lattice extension at the slinging points provided. Only use sling gear and joining elements of sufficient load bearing capacity.

In this way, you prevent the attached sections from slipping out, falling and causing injury during installation or removal.

Slinging points on the lattice extension sections Item no.

Part

The slinging points (A) and (B) are...

Angle piece

... on the connecting links and the struts.

6, 7

Intermediate sections

... in the central section.

8

Head

... on the top on each side.

9

Heavy load lattice extension adapter

... on the top on each side.

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5

3 - 12

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Operating instructions Boom extension, light GMK 6400

For operations planning 3.7 Transport

3.7

Transport You will find information for the safe transportation of lattice extension sections in this section. Also comply with the chapter Basic safety instructions.

Applicable for all sections

S G

Risk of damage to 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 lattice extension from tipping over and becoming damaged during transportation.

Risk of injury Before transport make sure that all pins are secured in the clamps with retaining pins. Secure the pins that are not secure.

This way you prevent the pins from falling down while driving and injuring or even killing other persons.

For the head

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The cable drum is locked with the spring latch (1).

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3 - 13

For operations planning 3.7 Transport

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Blank page

3 - 14

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Operating instructions Boom extension, light GMK 6400

4 Additional operating and display elements

4.1

Overview of the operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

1

4.1.1 4.1.2

On the crane control display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 On the RCL display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

1 2

4.2

Brief description of the operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

3

4.2.1 4.2.2

On the crane control display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 On the RCL display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

3 3

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4

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Operating instructions Boom extension, light GMK 6400

Additional operating and display elements 4.1 Overview of the operating elements

4

Additional operating and display elements If the GMK 6400 is equipped with the boom extension, light, there are additional or changed operating and display elements: On the crane control display:

– Displays in the Power unit speeds submenu, p. 4 - 1.

On the RCL display:

– The entries and display in the Enter rigging mode p. 4 - 2. submenu,

à

à

– Displays in the Monitoring submenu, p. 4 - 2.

à

Operating and display elements for other lattice extensions; extension operating manual.

4.1

Overview of the operating elements

4.1.1

On the crane control display

Power unit speeds submenu

Description of the displays;

à Lattice

à p. 4 - 3.

1 Displays for set luffing jib speed 2 Enter speeds for operation with lattice extension

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3 Display input mode on

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4-1

Additional operating and display elements 4.1 Overview of the operating elements

4.1.2

On the RCL display

Submenu for entering rigging mode

Description of the entries and displays;

à p. 4 - 3.

1 Display of current boom system 2 Lattice extension input 3 Main boom angle input

Submenu for RCL monitoring

Description of the displays;

à p. 4 - 4.

1 Lattice extension inclination display 2 Lattice extension length display

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3 Current main boom angle display

4-2

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Operating instructions Boom extension, light GMK 6400

Additional operating and display elements 4.2 Brief description of the operating elements

4.2

Brief description of the operating elements

4.2.1

On the crane control display

In the power unit speed submenu

Limiting the power unit speed

4.2.2

– Black:

Maximum speed for the power units with lattice extension can be set

– Light grey:

No setting possible

– Green:

Lattice extension is connected electrically, the crane control unit calculates with the value displayed

On the RCL display

Entering rigging mode in submenu Lattice extension input The button is only active if a lattice extension is electrically connected.

Black:

Button (3) is active

Light grey:

Button (3) has no function

– Input mode on:

– For boom system: Press button (3) until symbol (2) is green – For lattice extension length and angle: Press button (3) until symbol (1) is green

– Input:

In input mode, press button (3) once – next length or next angle on display (4)

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4-3

Additional operating and display elements 4.2 Brief description of the operating elements

Display of current boom system This display shows the boom that the RCL is currently recognising.

1 Main boom/auxiliary single-sheave boom top 2 Boom extension 2.1 Angle 2.2 Length Other displays for lattice extension; extension operating manual.

à Lattice

In the RCL monitoring submenu Lattice extension inclination display The lattice extension is connected.

– Display:

– With boom extension or heavy load lattice extension: Angle between lattice extension and main boom in degrees (°) – for displayed RCL code.

Lattice extension length display – Display:

Length of the lattice extension in metres (m) – for displayed RCL code.

Current main boom angle display Current angle between main boom and horizontal position in degrees (°)

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– Display:

4-4

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Operating instructions Boom extension, light GMK 6400

5 5

Boom extension, light

5.1

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1

5.1.1 5.1.2

CHECKLIST: Rigging the boom extension, light . . . . . . . . . . . . . . . . . . . . . . . . . 5 CHECKLIST: Unrigging the boom extension, light . . . . . . . . . . . . . . . . . . . . . . . 5 -

1 5

5.2

Description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

9

Installing/removing the rear pendant links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9 Pulling apart/pushing together intermediate sections . . . . . . . . . . . . . . . . . . . . 5 - 10 Rigging mode of the truck crane when installing and removing . . . . . . . . . . . . 5 - 13 Establishing/disconnecting the connections for the hydraulic lock . . . . . . . . . . 5 - 14 Securing/releasing locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16 Locking the adapter/releasing the pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17 Handling the pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19 Installing/removing boom extension sections . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20 Removing/installing the deflection sheave on the angle piece . . . . . . . . . . . . . 5 - 23 Replacing deflection sheaves on the angle piece . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24 Folding deflection sheaves up/down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25 Setting the angle position of the boom extension. . . . . . . . . . . . . . . . . . . . . . . . 5 - 27 Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 29 Connecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 31 Establishing/disconnecting the electrical connection . . . . . . . . . . . . . . . . . . . . . 5 - 32 Anemometer and air traffic control light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 34 Placing and reeving the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36

5.3

Operation with boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 41

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5

Operating the RCL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 42 RCL shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 46 Crane movements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 46 Telescoping with rigged boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 47 Checks when operating with the boom extension. . . . . . . . . . . . . . . . . . . . . . . . 5 - 48

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5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9 5.2.10 5.2.11 5.2.12 5.2.13 5.2.14 5.2.15 5.2.16 5.2.17

Operating instructions Boom extension, light GMK 6400

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.1 Checklists for rigging work

5

Boom extension, light

H

In order to simplify the text, the “boom extension, light” will be designated as just “boom extension” in the following chapter. The following chapter only relates to the boom extension, light.

5.1

Checklists for rigging work

5.1.1

CHECKLIST: Rigging the boom extension, light

H H

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

Observe the warnings and safety instructions specified here.

You will require an auxiliary crane and a hoisting platform for installing the boom extension.

1. Prepare the truck crane for the installation of the boom extension; Rigging mode of the truck crane when installing and removing, p. 5 - 13.

à

2. Remove the lifting limit switch on the main boom and insert the bridgGMK 6400 operating instrucing plug or block the lifting limit switch; tions – Installing/removing lifting limit switch.

à

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3. Place the parts in position in front of the main boom head according to the sequence in the assembly drawings;

à Notes on assembly, p. 3 - 2; à Combinations Type A and Type B, p. 3 - 4; à Combinations Type C, p. 3 - 6; à Slinging points, p. 3 - 12.

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s 5-1

Boom extension, light 5.1 Checklists for rigging work

4. Unreel the rigging rope up to the head and place it beside the parts that have been prepared.

5. Check, that the deflection sheaves on the adapter and the angle piece are folded up and are secured. If necessary, fold up and secure the Folding deflection sheaves up/down, p. 5 - 25. deflection sheaves;

à

6. Check, if the deflection sheave on the angle piece is installed in the heavy load lattice extension position; Replacing in heavy load lattice extension position, p. 5 - 24.

à

If necessary, install in the heavy load lattice extension position.

7. Set the 42° angle position, if necessary;

à p. 5 - 27.

8. Lift the adapter in front of the main boom head; Transport dimensions and weights, p. 3 - 8; Slinging points, p. 3 - 12.

à à

à p. 5 - 14.

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9. Establish connections for the adapter's lock;

5-2

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.1 Checklists for rigging work

10. Release and establish the lock between the adapter and the main boom head; Securing/releasing locks, p. 5 - 16; Locking the adapter/releasing the pin, p. 5 - 17.

à à

11. Disconnect connections for the adapter's lock;

à p. 5 - 14.

12. Unreel the cable from the drum in the head and connect it to the main boom. Do not lock the cable drum.

Establishing a connection, p. 5 - 32.

à

The cable must be be run inside the parts.

If required, remove the strain relief.

13. Lift and lock the other parts of the boom extension, one after the other.

While doing so, place the rigging rope on each of the assembled parts.

à Combinations Type A and Type B, p. 3 - 4; à Combinations Type C, p. 3 - 6; à Slinging points, p. 3 - 12; à Installing/removing boom extension sections, p. 5 - 20.

14. Enter the actual rigging mode with the rigged boom extension; Operating the RCL, p. 5 - 42.

GMK 6400 operating instructions – Rated capacity limiter – RCL.

à à

15. Enter the reeving needed for the planned operation on the RCL; GMK 6400 operating instructions – Operation of the RCL.

à

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5-3

Boom extension, light 5.1 Checklists for rigging work

16. Install the anemometer and if necessary establish an electrical connection for the air traffic control light; Installing, p. 5 - 34.

à

17. Install the lifting limit switch and the lifting limit switch weight on the head and connect the lifting limit switch; Installing lifting limit switch, p. 5 - 29.

à

18. Reeve the hoist rope on the hook block and place lifting limit switch Placing and reeving the hoist rope, weight around the hoist rope; p. 5 - 36.

à

19. Lock the cable drum in the head;

à Connecting cable, p. 5 - 31.

20. Raise the main boom with the boom extension.

21. If necessary, drive the rigged truck crane to the site; Permissible rigging modes and axle loads, p. 6 - 2.

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à

5-4

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.1 Checklists for rigging work

5.1.2

CHECKLIST: Unrigging the boom extension, light

H H

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

Observe the warnings and safety instructions specified here.

You will require an auxiliary crane and a hoisting platform for installing the boom extension.

1. Enter the current rigging mode with the rigged boom extension; p. 5 - 42, GMK 6400 operating instructions – Rated capacity limiter – RCL.

à à

2. If necessary, completely retract the main boom; Crane movements, p. 5 - 46.

à

3. Lower the main boom until the head touches the ground; Crane movements, p. 5 - 46.

à

4. Unreeve the hoist rope on the hook block.

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5-5

Boom extension, light 5.1 Checklists for rigging work

5. If required, remove the air traffic control light and put it away safely; Removing, p. 5 - 34.

à

6. Lock the cable drum in the head;

à Connecting cable, p. 5 - 31.

7. Remove the parts of the boom extension and place them on the ground.

Lower the main boom further. If required, unreel the cable drum in the head further.

8. Attach the adapter;

à Transport dimensions and weights, p. 3 - 8; à Slinging points, p. 3 - 12.

9. Establishing connection for the hydraulic lock of the adapter; p. 5 - 14.

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à

5-6

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.1 Checklists for rigging work

10. Release the hydraulic lock and lock between adapter and main boom head; Securing/releasing locks, p. 5 - 16; Locking the adapter/releasing the pin, p. 5 - 17.

à à

11. Disconnecting the connection for the hydraulic lock of the adapter; Establishing/disconnecting the connections for the hydraulic lock, p. 5 - 14.

à

12. Put down the adapter for transportation.

13. Fold the deflection sheaves on the adapter and on the angle piece for Folding back the deflection sheave, p. 5 - 26. the transport;

à

14. Attach the lifting limit switch from the head to the main boom head and place the and lifting limit switch weight around the hoist rope; GMK 6400 operating instructions – Installing/removing the lifting limit switch.

à

15. Reposition the anemometer from the head to the main boom head; GMK 6400 operating instructions – Anemometer.

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à

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5-7

Boom extension, light 5.1 Checklists for rigging work

16. Set the RCL code for the actual rigging mode with the main boom according to the lifting capacity table; GMK 6400 operating instructions – Rated capacity limiter – RCL.

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à

5-8

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

5.2

Description of the rigging work

5.2.1

Installing/removing the rear pendant links

Removing the rear pendant links

The rear pendant links must be removed to operate the the boom extension, light.

• Use an auxiliary crane with adequate lifting capacity; dimensions and weight of the parts;

à p. 3 - 8.

• Loosen the transport protection; à Rear pendant link transport protection, p. 5 - 10.

• Lift the rear pendant link from the rests.

• Check that the rear pendant links are removed on all the required sections of the boom extension.

• Set the rear pendant link down so that it is safe for transportation.

Installing the rear pendant links

• Use an auxiliary crane with adequate lifting capacity; dimensions and weight of the parts;

à p. 3 - 8.

• If required, fold out the rests.

• Loosen the transport protection; à Rear pendant link transport protection, p. 5 - 10.

• Lift the rear pendant link into the rests.

• Insert the transport protection; à Rear pendant link transport protection,

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p. 5 - 10.

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5-9

Boom extension, light 5.2 Description of the rigging work

5.2.2

Pulling apart/pushing together intermediate sections

Folding up/folding out the rests

Before the small intermediate sections are inserted into the large intermediate sections, the front rest of the rear pendant link must be folded in.

Folding out

• (A) – Hold the holder by the handle (1).

• Pull the pin out of the bore (3).

• (B) – Fold in the rest.

• Insert the pin into the bore (2).

Folding in

• (B) – Hold the rest by the handle (1).

• Pull the pin out of the bore (2).

• (A) – Fold in the rest.

• Insert the pin into the bore (3).

Rear pendant link transport protection

For transportation, the rear pendant links on the intermediate sections are secured by spring cotters.

You must remove the transport protection before removing the rear pendant links.

(A) – Inserting the transport protection

• Insert the spring cotter (2) into the bore of the pin (1).

• Secure the spring cotter.

(B) – Releasing the transport protection

• Release the spring cotter (2) from the pin (1).

• Fasten the spring cotter to a retaining pin or

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place the spring cotter in the driver's cab.

5 - 10

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

Pulling apart intermediate sections

• Secure the pin (1).

• Sling the small intermediate section (3) to the rear fork elements.

• Lift the small intermediate section (3) and pull it halfway out of the large intermediate section (2).

• The small intermediate section (3) rolls on the rollers (1).

• Sling the small intermediate section (3) onto the slinging points.

• Lift the small intermediate section (3) and pull it completely out of the large intermediate section (2).

• If necessary, install the rear pendant link onto the small intermediate section;

à Installing the rear pendant links, p. 5 - 9.

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5 - 11

Boom extension, light 5.2 Description of the rigging work

Pushing together intermediate sections

• If necessary, remove the rear pendant link from the small intermediate section.

• Install the rear pendant link onto the large intermediate section.

Installing/removing the rear pendant links;

à p. 5 - 9.

• Sling the small intermediate section (3) onto the slinging points.

• Lift the small intermediate section (3) and push it halfway into the large intermediate section (2).

The small intermediate section (3) rolls on the rollers (1).

• Sling the small intermediate sections (3) to the rear fork elements.

• Lift the small intermediate section (3) and push it completely into the large intermediate section (2).

• Insert the pin (1) into the connecting point

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and secure it.

5 - 12

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

5.2.3

G G

Rigging mode of the truck crane when installing and removing Risk of overturning The boom extension, the luffing jib and the heavy load lattice extension may only be rigged and operated with the specified span and the specified counterweight variant indicated in the Lifting capacity table.

Risk of accidents Use only the supplied and approved lifting gear of sufficient lifting capacity.

Use the supplied extendable ladder for installing/removing the boom extension as well as the mounted ladders and steps.

The following preparatory work must be carried out to put the truck crane in the prescribed rigging mode.

• Rig the truck crane; à Operating instructions, section CHECKLIST: Rigging

à

– required span Lifting capacity tables, – required counterweight combination

à Lifting capacity tables.

• Turn the superstructure in the direction required for rigging.

• Retract the main boom fully and derrick it to

à

the horizontal; GMK 6400 operating instructions – Telescoping mechanism.

• Unreeve the hook block;

à GMK 6400 operating instructions section

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Reeving and unreeving the hoist rope.

Lay the main hoist rope (1) on the head sheave (2) of the main boom.

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5 - 13

Boom extension, light 5.2 Description of the rigging work

5.2.4

Establishing/disconnecting the connections for the hydraulic lock

Establishing the connections Hydraulic connections

• Remove the hose lines (2) from the holder (3).

• Remove the protective caps from the hose lines (2) and the connections (1).

• Connect the hose lines (2) to the connections (1).

Electrical connections

• Remove the bridging plug (2) from the socket (1).

• Remove the cable (4) from the holder (5).

• Insert plug (3) in socket (1).

• Insert the plug of the control unit (6) into the socket (8).

You can lengthen the connecting cable of the control unit (6) using cable (7).

5 - 14

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S

Risk of damage to the connection lines Always disconnect the hydraulic and electrical connection immediately after you have locked the foot section. By doing this you prevent the connection lines tearing when telescoping or unrigging the foot section.

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

Disconnecting the connections

S

Risk of damage to the connection lines Always disconnect the hydraulic and electrical connection immediately after you have locked the foot section. By doing this you prevent the connection lines tearing when telescoping or unrigging the foot section.

Electrical connections

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

• Close the socket (3) with the protective cap and wind the cable (4) on the holder (5).

• Take the plug out of the socket (8) and close the socket with the protective cap.

• Put the cable (7) and the control unit (6) away, protected from bad weather.

Hydraulic connections

• Remove the hose lines (2) from the connections (1).

• Close the connections (1) and hose lines (2) with protective caps.

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• Fasten the hose lines (2) in the holder (3).

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5 - 15

Boom extension, light 5.2 Description of the rigging work

5.2.5

Securing/releasing locks You must release the

S

Lock:

To unlock the lock

Securing:

So that the lock cannot unlock by itself

Risk of accidents from unsecured lock.

Secure the lock immediately after you have locked the adapter. By doing so, you avoid that the locking pins unlock during operation.

(A) – Securing the lock

• Remove the pin (3) from the upper bore of the holder (4).

• Push the locking bar (1) on the handle (2) down.

The locking bar is in Secured position, if it is aligned with the lower bore on the holder (4).

• Insert the pin (3) into the lower bore and secure it with a linchpin.

(B) – Releasing the lock

• Remove the pin (3) from the lower bore of the holder (4).

• Push the locking bar (1) on the handle (2) up.

The locking bar is in Released position, if it is aligned with the upper bore on the holder (4).

• Insert the pin (3) into the upper bore and

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secure it with a linchpin.

5 - 16

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

5.2.6

Locking the adapter/releasing the pin

Prerequisites

• Check that – the hydraulic connection for locking is made; if required, make it; p. 5 - 14.

– the locking is released; release it if required; Securing/releasing locks, p. 5 - 16.

à

à

• Start the crane engine.

Locking the adapter

• Observe the prerequisites above. They must be fulfilled.

• Lift the adapter in front of the main boom such that the connection points (4) are Slinging points, p. 3 - 12. aligned;

à

For the upper pins:

• Place the lever (1) in position (A).

• Press the button (2) until the pins are fully extended.

• Lower the adapter such that the connection points (3) are aligned.

For the lower pins:

• Place the lever (1) in position (B).

• Press the button (2) until the pins are fully extended.

• Secure the lock; à p. 5 - 16.

S

Risk of accidents if the lock is released.

Secure the lock immediately after you have locked the adapter. By doing so, you avoid that the locking pins unlock during operation.

• Disconnect the connections for the hydraulic lock; à p. 5 - 14.

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5 - 17

Boom extension, light 5.2 Description of the rigging work

S

Risk of damage to the connection lines Always disconnect the hydraulic and electrical connection immediately after you have locked the adapter. By doing this you prevent the hoses and cables tearing when the main boom is telescoped.

• Remove the lifting gear.

Releasing the locking pin

• Observe the prerequisites above. They must be fulfilled.

• Lift the adapter to relieve the load on the pins; à Slinging points, p. 3 - 12.

For the upper pins

• Place the lever (1) in position (A).

• Press the button (2) until the pins are fully retracted.

For the lower pins

• Place the lever (1) in position (B).

• Press the button (2) until the pins are fully retracted.

• Disconnect the connections for the hydraulic lock;

S

à p. 5 - 14.

Risk of damage to the connection lines Always disconnect the hydraulic and electrical connection immediately after you have locked the foot section. By doing this you prevent the hoses and cables tearing when the foot section is lifted.

• Place the foot section on a separate vehicle using the auxiliary crane.

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• Remove the lifting gear.

5 - 18

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

5.2.7

Handling the pins Pins (1) They connect intermediate sections, adapter, angle piece and head.

They are tapered on both sides and are each secured with two retaining pins (2).

If the intermediate sections are unrigged, insert the pins in the holders (3) and (5).

Pins (4) When operating with luffing jibs, connect the rear pendant links.

If the rear pendant links are not required, the pins (4) are in the holder (5).

G

Danger of hands and arms being crushed.

Do not put your hand between the swinging parts in order to remove a bolt from the holder. To prevent your hands and arms from being crushed, remove the pin from the side of the part out of the holder.

When rigging

• (A) – Release only the inner retaining pin.

• (B) – Drive in the pin up to the outer retaining pin.

• Insert the inner retaining pin.

When unrigging

• (C) – Release only the outer retaining pin.

• Drive the bolt from the inside out.

• (D) – Insert the pin into the holder.

• Insert the outer retaining pin into the pin.

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The pin is now secured in the holder.

Operating instructions Boom extension, light GMK 6400

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5 - 19

Boom extension, light 5.2 Description of the rigging work

5.2.8

Installing/removing boom extension sections

Before installation

• For installing/removing, use an auxiliary crane with adequate lifting capacity; – Dimensions and weight of the sections; p. 3 - 12.

– Slinging points;

à

à p. 3 - 8,

• Use a hoisting platform for installing/removing.

• Check that – the rear pendant links are removed on all the required sections of the p. 5 - 9. boom extension;

à

G

Risk of accidents due to non-determinable loads Operation with the boom extension is prohibited if the rear pendant links are fastened to the intermediate sections.

The weight of the rear pendant links cannot be determined by the RCL. Thus, a RCL shutdown at the right time is no longer guaranteed. The truck crane is overloaded.

• Check that – the cable from the cable drum is laid inside the parts of the boom extension. p. 5 - 32.

– the electrical connection has been established;

à

S

Risk of damage to electric lines Lock the cable drum in the head when the plug of the cable is inserted in the main boom. If the cable drum is not locked, it can accidentally turn. This will damage the plug on the cable drum.

à p. 5 - 19.

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Information on operating the pins;

5 - 20

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

Installing

• Install the adapter of the heavy load lattice extension.

• Using the auxiliary crane, install the next part on the adapter by establishing the connections in the top and bottom chords. To do so, raise the main boom.

• Lift the section in front of the last section to be rigged so that the upper connecting points (1) and (2) align first.

• Insert the holder's pins (3) and (4) in the connecting points (1) and (2) and secure them with retaining pins.

• lower the last section, until the connecting points (5) and (3) align.

• Insert the holder's pins (6) and (4) in the connecting points (5) and (3) and secure them with retaining pins.

• Install the other parts of the boom extension in the same way. If an angle is to be set on the angle piece, set it before the angle piece is lifted.

Always take care that the cable to the main boom head is not damaged.

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Operating instructions Boom extension, light GMK 6400

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5 - 21

Boom extension, light 5.2 Description of the rigging work

Removing

For removal, you must begin from the front and release the connecting points on the individual parts and put away the parts individually.

G

Risk of accidents if the boom extension moves unexpectedly Before you release the pin connections, first relieve the boom extension by derricking the main boom or by lifting using the auxiliary crane until the pins move easily.

In this way you avoid the loaded boom extension folding down when detaching the connection and hurting yourself or others.

• Lower the main boom until the first part is just above the ground.

• Attach the first part.

• Release the connections in the bottom chord.

• Lift the part until the connections in the top chord can be released easily.

• Detach the connections in the top chord.

• Set the part down. Always take care that the cable to the main boom head is not damaged.

• Lower the main boom until the second part is just above the ground.

• Attach the second part.

• Remove the other parts of the boom extension in the same way.

à

• Release the plug on the cable drum. An error message appears.

• Unlock the cable drum.

• Unreel the cable.

• Lock the cable drum.

• Insert the plug into the cable drum socket.

• Acknowledge the error message.

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H

If the cable to the main boom head is unreeled, proceed as follows ( Establishing/disconnecting the electrical connection, p. 5 - 32):

5 - 22

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

5.2.9

Removing/installing the deflection sheave on the angle piece The deflection sheave can be removed for transportation.

Removing

• (A) – Sling the deflection sheave at the holding roller (1); à Transport dimensions and weights, p. 3 - 8.

• Pull the pins (2) out of the connecting points (3).

• (B) – Lift off the deflection sheave from the angle piece.

• Insert the pins (2) into the connecting points of the deflection sheave and secure them with the retaining pins.

• Remove the lifting gear.

Installing

• (A) – Sling the deflection sheave at the holding roller (1).

• Remove the pins (2) from the bearing points.

• (B) – Position the deflection sheave so that

à

Replacing the required brackets (3) align; in heavy load lattice extension position, p. 5 - 24.

• Lock the deflection sheave in this position with the pins (2) and secure them with retaining pins.

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• Remove the lifting gear.

Operating instructions Boom extension, light GMK 6400

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5 - 23

Boom extension, light 5.2 Description of the rigging work

5.2.10

Replacing deflection sheaves on the angle piece The deflection sheave on the angle piece can be mounted in two ways.

– (A) – Position Boom extension/luffing jib.

– (B) – Position Heavy load lattice extension (additional equipment).

Replacing in heavy load lattice extension position

• (A) – Sling the deflection sheave at the holding roller (1).

• Pull the pins (2) out of the connecting points (3).

• (B) – Position the deflection sheave so that the brackets (4) align.

• Insert the pins (2) into the connecting points (4) and secure them with retaining pins.

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• Remove the lifting gear.

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

5.2.11

Folding deflection sheaves up/down There are foldable deflection sheaves on the foot section and on the angle piece. All deflection sheaves are folded in the same way.

On the angle piece Folding back the deflection sheave

• (A) – Hold the deflection sheave (2) tightly.

• Remove the pin from the connecting point (1).

• (B) – Fold the deflection sheave (2) to the side.

• Insert the pin into the connecting point (1) and secure it with a retaining pin.

Folding up the deflection sheave

• (A) – Pull the pin out of the connecting point (1).

• (B) – Fold the deflection sheave (2) upwards.

• Insert the pin into the connecting point (1) and secure it with a retaining pin.

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5 - 25

Boom extension, light 5.2 Description of the rigging work

On the adapter Folding back the deflection sheave

• (A) – Hold the deflection sheave (2) tightly.

• Remove the pin from the connecting point (3).

• (B) – Fold the deflection sheave (2) to the side until the bores on the connecting points (1) align.

• Insert the pin into the connecting point (1) and secure it with a retaining pin.

Folding up the deflection sheave

• (A) – Pull the pin out of the connecting point (1).

• (B) – Fold the deflection sheave (2) upwards.

• Insert the pin into the connecting point (3)

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and secure it with a retaining pin.

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

5.2.12

Setting the angle position of the boom extension Setting 20° angle

• Derrick the main boom until the bores (1) align.

Carry out the following instructions on the right and the left side.

• Remove the pin from the holder (2).

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

Setting 42° angle

• Set the boom extension down onto the head.

Carry out the following instructions on the right and the left side.

• Remove the pin from the bore (1).

• Insert the pin into the holder (2) and secure it with a retaining pin.

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G

Risk of accidents because of faulty fall-back guard strut The pendulums of the fall-back guard struts on both sides of the angle piece have to be freely movable throughout their entire slewing range.

If the pendulum is not able to move freely over the entire slewing range, the boom extension will not be supported to the rear.

Furthermore, the fall-back guard strut can be damaged when the boom extension is set down.

s Operating instructions Boom extension, light GMK 6400

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5 - 27

Boom extension, light 5.2 Description of the rigging work

• Check if the pendulums (1) of the fall-back guard struts on both sides of the angle piece can move freely.

If the fall-back guard strut is not freely movable:

• Do not raise the main boom.

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Have it repaired or inform Manitowoc Crane Care.

5 - 28

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

5.2.13

Installing/removing the lifting limit switch

Installing lifting limit switch

Connection to the main boom Remove the lifting limit switch on the main boom; instructions.

à GMK 6400 operating

If the lifting limit switch is removed from the main boom, both connections GMK 6400 operating instructions. must be bridged (1);

à

If a lifting limit switch remains attached to the main boom, the lifting limit GMK 6400 operating instructions. switch must be disabled;

à

Mount lifting limit switch to head

• Fit the lifting limit switch (3) on to the holder (2) and secure it with a retaining pin.

• Connect the lifting limit switch (3) to the socket (1).

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5 - 29

Boom extension, light 5.2 Description of the rigging work

Removing the lifting limit switch

• Pull the plug from the socket (1).

• Cover the socket (1) with the protective cap.

• Remove the lifting limit switch (3) from the clamp (2).

• Fasten the retaining pin to the lifting limit

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switch.

5 - 30

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

5.2.14

Connecting cable The connecting cable is wound onto a cable drum in the head.

For transport and operation, the cable drum is locked with the spring latch (1).

(A)

Unlocked

(B)

Locked

For winding on and unwinding

• Unlock the cable drum.

For operation and transport:

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• Lock the cable drum.

Operating instructions Boom extension, light GMK 6400

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5 - 31

Boom extension, light 5.2 Description of the rigging work

5.2.15

Establishing/disconnecting the electrical connection

Establishing a connection

• Pull the plug (3) from the socket.

• Unlock the cable drum (2); à Connecting cable, p. 5 - 31.

• Unwind the connecting cable from the cable drum and pull it through the lattice extension sections up to the main boom head.

• Attach the strain relief to the holder (1) on the adapter.

• Lock the cable drum; à Connecting cable, p. 5 - 31.

• Insert the plug (3) into the cable drum socket.

• Remove the bridging plug (3) from the socket (5) and plug it into the dummy socket (6).

• Connect the connecting cable to the plug (2)

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on the cable drum.

5 - 32

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

Disconnecting

• Pull the plug from the socket (3) and close the socket with the protective cap.

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

• Release the strain relief to the holder (7) on the adapter.

• Remove the plug (5) from the socket (4).

• Unlock the cable drum (6); à Connecting cable, p. 5 - 31.

• Wind the connecting cable onto the cable drum.

• Lock the cable drum; à Connecting cable, p. 5 - 31.

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• Insert plug (2) in socket (3).

Operating instructions Boom extension, light GMK 6400

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5 - 33

Boom extension, light 5.2 Description of the rigging work

5.2.16

Anemometer and air traffic control light

Installing

Remove the anemometer from the main boom; instructions.

à GMK 6400 operating

• Insert the rod (3) into the holder (5) and secure it with the retaining pin.

• Remove the cable from the holders (4) and connect – the anemometer to socket (1), – the air traffic control light to the socket (2).

• Lay the cables in such a way that they will not be damaged during crane operation.

• Check that the anemometer is able to swing so that it hangs vertically even when the main boom is raised.

Removing

• Remove the plug and close the sockets (1) and (2) with the protective caps.

• Wind the cables onto the holders (4).

• Take the rod (3) out of the holder (5).

• For transportation, fasten the retaining pins

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to the rod (3).

5 - 34

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

S

Risk of accidents from unsecured lock.

Secure the lock immediately after you have locked the adapter. By doing so, you avoid that the locking pins unlock during operation.

(A) – Securing the lock

• Remove the pin (3) from the upper bore of the holder (4).

• Push the locking bar (1) on the handle (2) down.

The locking bar is in Secured position, if it is aligned with the lower bore on the holder (4).

• Insert the pin (3) into the lower bore and secure it with a linchpin.

(B) – Releasing the lock

• Remove the pin (3) from the lower bore of the holder (4).

• Push the locking bar (1) on the handle (2) up.

The locking bar is in Released position, if it is aligned with the upper bore on the holder (4).

• Insert the pin (3) into the upper bore and

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secure it with a linchpin.

Operating instructions Boom extension, light GMK 6400

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5 - 35

Boom extension, light 5.2 Description of the rigging work

5.2.17

G

Placing and reeving the hoist rope Risk of accidents if the deflection sheave is in the wrong position.

Check if it is locked in the heavy load lattice extension position; p. 5 - 24.

This avoids damage to the hoist rope by dragging on the structural members which can lead to the load falling.

à

• Remove the rope holding rods (3) and (4).

• Secure the pin (1).

• Fold out the rope guide bar (2).

• Lay the hoist rope over the deflection sheaves (8), (7), (9) and (5).

• Place the hoist rope into the rests (11) on the intermediate sections. The rope may not lie in the rests (10) for the rear pendant links.

• Guide the hoist rope down over the right

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head sheave (6).

5 - 36

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

• Insert the rope holding rods (3) and (4) in the holders and secure them with the spring cotters.

• Reeve the hoist rope, possible reevings;

à p. 5 - 36.

• Secure the rope end clamp to the hook block or the attachment plate (5) on the head, depending on the reeving method used.

• Fold in the rope guide bar (2) and secure it with the pin (1) and the spring cotter.

• Check that the locking on the lifting limit switch has been released; GMK 6400 operating instructions – Reeving and unreeving the hoist rope.

à

• Suspend the lifting limit switch weight and place it around the hoist rope;

à GMK 6400 operating instructions – Reeving and unreeving the hoist rope.

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Operating instructions Boom extension, light GMK 6400

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5 - 37

Boom extension, light 5.2 Description of the rigging work

Possible reevings

Reeving the hoist rope into the hook block; tions.

à GMK 6400 operating instruc-

• Secure the rope end clamp to the hook block (2) or the attachment plate (1) on the head, depending on the reeving method used.

5 sheave hook blocke Maximum lifting capacity of the hook block: 160 t Max. lifting capacity with the GMK 6400 Reeving

Maximum lifting capacity

A

8x

98.8 t

B

7x

86.7 t

3 sheave hook blocke Maximum lifting capacity of the hook block: 100 t Max. lifting capacity with the GMK 6400 Maximum lifting capacity

A

6x

74.6 t

B

5x

62.4 t

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Reeving

5 - 38

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.2 Description of the rigging work

3 sheave hook blocke Maximum lifting capacity of the hook block: 100 t Max. lifting capacity with the GMK 6400 Reeving

Maximum lifting capacity

A

50.1 t

4x

1 sheave hook blocke Maximum lifting capacity of the hook block: 40 t Max. lifting capacity with the GMK 6400 Reeving

Maximum lifting capacity

A

3x

37.7 t

B

2x

25.2 t

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Operating instructions Boom extension, light GMK 6400

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5 - 39

Boom extension, light 5.2 Description of the rigging work

Hook tackle Maximum lifting capacity of the hook tackle: 16 t Max. lifting capacity with the GMK 6400 Reeving

Maximum lifting capacity

A

12.7 t

1x

In the case of long lattice extensions:

• Attach a load of at least 450 kg.

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S

Risk of rope slack occurring.

When working with single-line reeving with long lattice extensions, you must lift a load of at least 450 kg. This means that the weight of the rear hoist rope is compensated and no slack rope develops.

Observe the specifications for working with luffing jibs in the lifting capacity tables.

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.3 Operation with boom extension

5.3

Operation with boom extension

Risk of the main boom buckling.

Accelerate and brake the crane movements in such a way that the load does not sway.

Risk of accidents due to overload.

A hook block must not be reeved on the main boom during operation with the boom extension. This hook block or load is not detected by the RCL and the truck crane can become overloaded.

Risk of rope slack occurring.

When working with single-line reeving with long lattice extensions, you must lift a load of at least 450 kg. This means that the weight of the rear hoist rope is compensated and no slack rope develops.

Observe the specifications for working with luffing jibs in the lifting capacity tables.

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S S G S

Risk of overturning due to excessively high wind speeds.

If the maximum permissible wind speed according to the Lifting capacity table is reached, you must put down the load. The crane can be overloaded.

Please observe the notes in the Lifting capacity table.

Operating instructions Boom extension, light GMK 6400

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5 - 41

Boom extension, light 5.3 Operation with boom extension

5.3.1

Operating the RCL

Entering the RCL code

• Enter: – The RCL code as described in the Lifting capacity table and the current reeving; GMK 6400 operating instructions, or – Enter the components of the current rigging mode; following chapter.

à

à

Entering components

Enter the components in the following sequence: GMK 6400 operating instructions 1 Counterweight

à 2 Angle and length of the boom exten- à Angle, p. 5 - 42 à Length, p. 5 - 43 sion 3 Reeving à GMK 6400 operating instructions

If the rigged lattice extension is connected electrically, the detected lattice extension is shown on display (2); here: the boom extension.

In addition, the symbol (1) is shown in black.

H

The following two sections only describe the selection of the components.

While selecting, you will be given information that is described in the folAdditional information on selection, p. 5 - 43. lowing section;

à

Angle

• Repeatedly press button (3) until symbol (1) turns green.

• Repeatedly press buttons (2) until display (4) shows the required angle (0°, 22°).

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Display (5) always shows the value 20°.

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.3 Operation with boom extension

Length

• Repeatedly press button (3) until symbol (1) turns green.

• Repeatedly press buttons (2) until display (4) shows the required length (e.g. 13 m).

Additional information on selection When selecting a new lattice extension, display (2) shows the corresponding RCL code directly.

Display (1) shows the corresponding value for the maximum load that can be lifted with the RCL code displayed in accordance with the reeving entered and the current telescoping.

H

For Type B and Type C light boom extensions, the specifications for length and angle are the same. Therefore, observe the RCL code (e.g. at 13 m 42° with 9916 for Type B and 9922 for Type C) as additional information.

If a rigging mode which is not permitted is displayed (values 1000 and 0000), you will not be able to accept the values. In this case, the button (1) has no function.

When all the new values have already been entered, and a permitted rigging mode is displayed, you can accept the values shown; GMK 6400 operating instructions.

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à

s Operating instructions Boom extension, light GMK 6400

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5 - 43

Boom extension, light 5.3 Operation with boom extension

Accepting the rigging mode

G

• Check whether the current rigging mode of the truck crane corresponds to the displayed rigging mode.

Risk of accidents due to incorrectly set RCL. If the current rigging mode varies from the displayed rigging mode, the maximum load displayed by the RCL will not correspond to the actually permissible lifting capacity according to the Lifting capacity table.

Overloading and accidents will be the certain result.

Only the display for the current rigging mode of the boom extension is described below. The display for the other components; GMK 6400 operating instructions.

à

• Check it according to the lifting capacity table: 1 The rigged angle1) 2 The rigged length 3 The RCL code1) 1) according to the lifting capacity table

For the rigging mode, the following is displayed: A The permissible working range of the lattice extension B The RCL code C The permissible working range of the main boom

• If you need to correct the values, press button (1).

The Enter rigging mode submenu opens.

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If the current rigging mode is displayed, press button (1). The Monitoring submenu opens and the crane movements are enabled provided no error is pending.

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.3 Operation with boom extension

Checks and displays in the Monitoring submenu

G

• Check whether the current rigging mode of the truck crane corresponds to the displayed rigging mode.

Risk of accidents due to incorrectly set RCL. If the current rigging mode varies from the displayed rigging mode, the maximum load displayed by the RCL will not correspond to the actually permissible lifting capacity according to the Lifting capacity table.

Overloading and accidents will certainly be the result.

• Check: 1 The rigged angle 2 The rigged length of the boom extension 3 The RCL code 4 The number of reeved rope lines 5 The hoist that is switched on 6 The rigged counterweight 7 The rigged outrigger span

Hoists display The lamp that lights up must always be for the hoist with which the load is to be lifted: Lamp I:

Must go on if the load is to be raised with the main hoist.

Lamp II:

Must go on if the load is to be raised with the auxiliary hoist.

• Switch over the display if necessary; à Operating instructions.

• If you need to correct the values, press the button (1) and open the Enter rigging mode submenu.

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You can start working with the crane if the current rigging mode of the truck crane is displayed.

Operating instructions Boom extension, light GMK 6400

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5 - 45

Boom extension, light 5.3 Operation with boom extension

5.3.2

RCL shutdown The RCL will shut down due to overload if you do not stop the current crane operation after receiving an RCL early warning and if about 100% of the maximum permitted load is exceeded. In the event of a shutdown due to overload: – All crane movements which increase the load moment are switched off.

– The continuous buzzer tone sounds.

– The warning lamp (1) lights up.

• Leave the shutdown range by raising the main boom. If necessary, set down the load to do so.

à

GMK 6400 operating instrucFurther information for operating the RCL; tions – Operating the rated capacity limiter (RCL).

5.3.3

Crane movements When operating the boom extension, all crane movements are controlled in the same way as when operating the main boom. Some crane movements are blocked by the crane control when operating the boom extension.

Enabled crane movements

Disabled crane movements

– Lifting/lowering the main hoist

– Telescoping out/in1)

– Lifting/lowering the auxiliary hoist – Lowering/raising – Slew 1)

Telescoping is only enabled given certain prerequisites; with rigged boom extension, p. 5 - 47.

à Telescoping

If there is an overload, the RCL blocks load-increasing crane movements; GMK 6400 operating instructions – RCL shutdown.

H 5 - 46

When working with the boom extension, the high-speed mode for the derricking gear is locked by the crane control.

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Operating instructions Boom extension, light GMK 6400

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à

Boom extension, light 5.3 Operation with boom extension

5.3.4

Telescoping with rigged boom extension Telescoping of the main boom with a rigged boom extension is monitored by the RCL. Telescoping will only be enabled if the main boom is derricked to a certain angle and a maximum permissible load is not exceeded. The required angle depends on: – The length of the boom extension – The extended length of the main boom – The rigged counterweight.

You will find the required main boom angle and the maximum permissible load (weight of the hook block) in the Lifting capacity tables, in chapter Rigging tables of the boom extension).

The superstructure should not be turned while the main boom is being telescoped. The maximum permissible slewing speed is automatically limited to 10%.

While the main boom is being telescoped, the high-speed mode for the hoist, derricking gear or telescoping cannot be used. The speeds are automatically limited.

The telescoping mechanism is operated in the same way as the main boom;

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à GMK 6400 operating instructions – Auxiliary hoist.

Operating instructions Boom extension, light GMK 6400

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5 - 47

Boom extension, light 5.3 Operation with boom extension

5.3.5

Checks when operating with the boom extension

Horizontal alignment

During crane operation, the truck crane may tilt if the ground gives way due to varying loads.

G

Risk of accidents if the truck crane is not level.

The RCL calculates the working radius from the length and angle of the main boom. The actual working radius changes and there is a danger of the crane overturning if the truck crane is not level.

• Check the horizontal alignment of the truck crane during crane operation on the display (1).

You will find further information on this in the Operating instructions chapter Checks during crane operation.

Checking the wind speed

Strong winds can result in the truck crane becoming overloaded.

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

Maximum permissible wind speed The maximum permissible wind speed (1) for the current rigging mode is specified at the bottom of the corresponding Lifting capacity table.

In certain cases, the specified permissible wind speed must be reduced; Lifting capacity table.

à

Current wind speed The current wind speed is displayed in the main menu and in the Telescoping submenu. The colour of the bar (1) changes depending on the displayed range.

Green bar

6 to 12 m/s:

Yellow bar

over 12 m/s:

Red bar

The colour of the bar only depends on the value of the current wind speed.

The maximum permissible wind speed does not affect the colour of the bar.

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H

0 to 6 m/s:

5 - 48

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Operating instructions Boom extension, light GMK 6400

Boom extension, light 5.3 Operation with boom extension

If the maximum permitted wind speed is exceeded No automatic shutdown occurs if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

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

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G

Risk of accidents from excessively high wind speeds If the current wind speed is higher that the maximum permissible wind speed, immediately stop operating the crane and set up the corresponding rigging mode Lifting capacity table.

This will prevent the truck crane from overturning due to overload.

Operating instructions Boom extension, light GMK 6400

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5 - 49

Boom extension, light 5.3 Operation with boom extension

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5 - 50

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Operating instructions Boom extension, light GMK 6400

6 6

Driving with a rigged truck crane

6.1

Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

2

6.2

Permissible rigging modes and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

2

6.3

Before driving the rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

3

6.4

Driving the rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

3

6.5

Tables with boom positions and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

5

Driving with rigged truck crane with Mega Wing Lift . . . . . . . . . . . . . . . . . . . . . 6 - 6 Driving with rigged truck crane without Mega Wing Lift . . . . . . . . . . . . . . . . . . 6 - 15

10.12.2014

6.5.1 6.5.2

Operating instructions Boom extension, light GMK 6400

3 113 164 en

10.12.2014

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane

6

Driving with a rigged truck crane

Risk of accidents due to partially obstructed view of the truck crane While driving, always stay in visual or radio contact with a banksman who can observe the parts which you cannot see.

Risk of overturning by slewing superstructure When driving with a rigged truck crane – the slewing gear must be switched off and – the superstructure must be locked.

Risk of accidents when driving on public roads Driving on public roads with a rigged truck crane is not permitted.

Risk of accidents when driving with a lifted load Driving the truck crane with a load lifted is prohibited. Always set down the load prior to driving the truck crane and secure the hook block so it cannot swing.

Danger of accidents due to sinking ground Note the load bearing capacity of the ground when driving the rigged truck crane. If the surface pressure of the tyres exceeds the permissible load on the ground, the surface area of the tyres must be increased by packing stable material (e.g. wooden planks).

Risk of damage to the axle lines Only bring the superstructure and the main boom into the specified positions. This prevents excessive strain on the axle lines.

10.12.2014

G G G G G G S

Danger of tipping when driving the rigged truck crane Driving with a rigged truck crane is an operating mode which must be carried out with the utmost care. Therefore, observe the safety instructions relating to this in the chapter Driving with rigged truck crane GMK 6400 operating instructions.

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6-1

Driving with a rigged truck crane 6.1 Driving distance

6.1

Driving distance The driving path must be even. The level adjustment system cannot compensate for uneven surfaces.

The ground of the driving distance must be stable enough to bear the axle loads.

If the surface pressure of the tyres exceeds the permissible load on the ground, the surface area of the tyres must be increased by packing stable material (e.g. wooden planks).

6.2

Permissible rigging modes and axle loads

S

Risk of damage to the axle lines Bring the superstructure and the main boom into the prescribed positions only. This prevents excessive strain on the axle lines. The prescribed positions; Tables with boom positions and axle loads in section 6.5.

à

Rigging modes Prerequisite: The truck crane is supported on outriggers.

• Set down the load. You must not raise any load other than the hook block.

• Reeve larger hook blocks rather than those permitted.

Permitted hook blocks;

à p. 6 - 5.

• Put the main boom and boom extension into the prescribed position;

à p. 6 - 5.

• If required, unrig the counterweight; max. counterweight; à p. 6 - 5.

• Enter the RCL code in accordance with Lifting capacity table for the current working position.

• Switch off the slewing gear; à GMK 6400 operating instructions.

• Lock the superstructure; à GMK 6400 operating instructions.

10.12.2014

• Tie down the hook block so that it cannot swing back and forth.

6-2

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.3 Before driving the rigged truck crane

6.3

Before driving the rigged truck crane • Check the tyre pressure and the wind speed; à GMK 6400 operating instructions.

• Check that

à

– the slewing gear is switched off; GMK 6400 operating instructions – the superstructure is locked; GMK 6400 operating instructions.

à

• Place the truck crane on the wheels; à GMK 6400 operating instructions.

The suspension is switched off.

• For reasons of safety, extend the outrigger beams in accordance with the available space. The outrigger pads may not touch the ground while driving the crane.

6.4

Driving the rigged truck crane

Driving from the driver's cab

• Engage the lowest starting gear; à GMK 6400 operating instructions.

In this way you prevent the gears changing up and ensure that the speed is kept to a minimum.

• Switch on the separate steering; à GMK 6400 operating instructions.

If required, you can – switch on the longitudinal differential locks, – switch on the transverse differential locks.

While driving

G

Risk of accidents when driving with a lifted load The maximum permissible speed for driving with a lifted load is 1.5 km/h.

• Only drive slowly, do not change up.

• The turning radius should be as great as possible when driving around corners.

• Only steer the truck crane when it is rolling and avoid sudden steering

10.12.2014

changes.

S

Risk of damage to the steering linkage The steering linkage can be damaged if the steering wheel is moved while the vehicle is stationary.

Operating instructions Boom extension, light GMK 6400

s 3 113 164 en

6-3

Driving with a rigged truck crane 6.4 Driving the rigged truck crane

G

Danger of overturning by switching on the suspension The suspension must be deactivated (locked) while the rigged truck crane is on wheels.

Switching on the suspension would cause the suspension cylinders to be suddenly pressed together and damaged, and the truck crane could overturn.

10.12.2014

Never align the truck crane with the level adjustment system if the ground is uneven. In this case you must raise the truck crane with the supporting cylinders, level it and then re-lower it.

6-4

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

6.5

Tables with boom positions and axle loads

Information about the tables

The axle loads specified in the tables in section 6.5 relate to – a driving mode with the basic unit and – to the specified, maximally reeved hook block or hook tackle. Larger hook blocks must be unreeved.

The following applies to the footnotes in the tables in section 6.5: 1)

2)

Display, slewing angle 0°

Front:

Display, slewing angle 180°

Front:

On the first and second axle line respectively

Rear:

On the third, fourth, fifth and sixth axle lines respectively

Counterweight combination set down on the counterweight platform

10.12.2014

3)

Rear:

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6-5

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Main boom angle in °

Lattice extension angle in °

Superstructure position1)

0-0-0-0

25

42

front

15,0

20,5

0-0-0-0

82

42

rear

10,0

23,0

0-0-0-0

25

42

front

11,5

24,5

0-0-0-0

82

42

rear

12,5

24,0

front

--

--

rear

15,5

25,5

front

--

--

rear

18,0

26,5

not permitted

front

--

--

not permitted

rear

--

--

not permitted 0-0-0-0

82

42

not permitted

55

0-0-0-0

75 over 55 t

I - II - III - IV in %

set down or raised 3)

35

45

front

Telescope status

25

Axle load 2) in t

Boom extension, light, 2,3 + 11 m 42°

Position of the MWL

Driving with rigged truck crane with Mega Wing Lift

Counterweight in t

6.5.1

82

42

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1), 2)

Gantry masts folded in or out

10.12.2014

3)

à Information about the tables, p. 6 - 5

6-6

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

Main boom angle in °

Lattice extension angle in °

Superstructure position1)

0-0-0-0

25

20

front

15,0

20,5

0-0-0-0

82

20

rear

10,5

22,5

0-0-0-0

25

20

front

11,5

24,5

0-0-0-0

82

20

rear

13,0

24,0

front

--

--

rear

16,0

25,0

front

--

--

rear

18,5

26,0

not permitted

front

--

--

not permitted

rear

--

--

not permitted 0-0-0-0

82

20

not permitted

55

0-0-0-0

75 over 55 t

I - II - III - IV in %

set down or raised 3)

35

45

front

Telescope status

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Position of the MWL

Counterweight in t

Boom extension, light, 2,3 + 11 m 20°

82

20

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1), 2)

Gantry masts folded in or out

10.12.2014

3)

à Information about the tables, p. 6 - 5

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6-7

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

Main boom angle in °

Lattice extension angle in °

Superstructure position1)

0-0-0-0

15

42

front

17,0

19,5

0-0-0-0

82

42

rear

10,0

23,0

0-0-0-0

15

42

front

13,5

23,5

0-0-0-0

82

42

rear

12,5

24,0

front

--

--

rear

15,5

25,5

front

--

--

rear

18,0

26,5

not permitted

front

--

--

not permitted

rear

--

--

not permitted 0-0-0-0

82

42

not permitted

55

0-0-0-0

75 over 55 t

I - II - III - IV in %

set down or raised 3)

35

45

front

Telescope status

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Position of the MWL

Counterweight in t

Boom extension, light, 8,3 + 5 m 42°

82

42

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1), 2)

Gantry masts folded in or out

10.12.2014

3)

à Information about the tables, p. 6 - 5

6-8

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

set down or raised 3)

35

Axle load 2) in t

Superstructure position1)

Lattice extension angle in °

rear

front

--

--

82

42

rear

9,0

23,5

0-0-0-0

25

42

front

13,0

24,0

0-0-0-0

82

42

rear

11,5

25,0

front

--

--

rear

14,5

26,0

front

--

--

rear

17,0

27,0

not permitted

front

--

--

not permitted

rear

--

--

0-0-0-0

82

42

not permitted 0-0-0-0

75

front

0-0-0-0

not permitted

55

over 55 t

Main boom angle in °

Telescope status

not permitted

25

45

I - II - III - IV in %

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Position of the MWL

Counterweight in t

Boom extension, light, 2,3 + 17 m 42°

82

42

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1), 2)

Gantry masts folded in or out

10.12.2014

3)

à Information about the tables, p. 6 - 5

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6-9

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

set down or raised 3)

35

Axle load 2) in t

Superstructure position1)

Lattice extension angle in °

rear

front

--

--

82

20

rear

10,0

23,0

0-0-0-0

12

20

front

15,0

23,0

0-0-0-0

82

20

rear

12,5

24,5

0-0-0-0

25

20

front

11,0

27,5

0-0-0-0

82

20

rear

15,0

25,5

front

--

--

rear

17,5

26,5

not permitted

front

--

--

not permitted

rear

--

--

0-0-0-0

75

front

0-0-0-0

not permitted

55

over 55 t

Main boom angle in °

Telescope status

not permitted

25

45

I - II - III - IV in %

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Position of the MWL

Counterweight in t

Boom extension, light, 2,3 + 17 m 20°

82

20

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1), 2)

Gantry masts folded in or out

10.12.2014

3)

à Information about the tables, p. 6 - 5

6 - 10

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

set down or raised 3)

35

Axle load 2) in t

Superstructure position1)

Lattice extension angle in °

rear

front

--

--

82

42

rear

9,5

23,5

0-0-0-0

25

42

front

14,0

23,5

0-0-0-0

82

42

rear

12,0

24,5

0-0-0-0

15

42

front

12,0

27,0

0-0-0-0

82

42

rear

14,5

26,0

front

--

--

rear

17,0

27,0

not permitted

front

--

--

not permitted

rear

--

--

0-0-0-0

75

front

0-0-0-0

not permitted

55

over 55 t

Main boom angle in °

Telescope status

not permitted

25

45

I - II - III - IV in %

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Position of the MWL

Counterweight in t

Boom extension, light, 14,3 + 5 m 42°

82

42

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1), 2)

Gantry masts folded in or out

10.12.2014

3)

à Information about the tables, p. 6 - 5

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 11

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

Superstructure position1)

--

not permitted

rear

--

--

front

15,5

23,0

25

Lattice extension angle in °

--

Main boom angle in °

front

42

set down or raised 3)

not permitted 0-0-0-0

25

42

front

11,5

27,5

0-0-0-0

82

42

rear

13,0

27,0

front

--

--

rear

15,5

28,0

not permitted

front

--

--

not permitted

rear

--

--

0-0-0-0

75

rear

rear

not permitted

55

over 55 t

not permitted

0-0-0-0

35

45

front

I - II - III - IV in %

Telescope status

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Position of the MWL

Counterweight in t

Boom extension, light, 2,3 + 23 m 42°

82

42

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1), 2)

Gantry masts folded in or out

10.12.2014

3)

à Information about the tables, p. 6 - 5

6 - 12

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

45

set down or raised 3)

35

Superstructure position1)

--

--

not permitted

rear

--

--

Lattice extension angle in °

front

Main boom angle in °

not permitted

25

20

front

15,5

23,0

0-0-0-0

82

20

rear

11,5

25,0

0-0-0-0

25

20

front

11,5

27,5

0-0-0-0

82

20

rear

14,0

26,0

front

--

--

rear

16,5

27,5

not permitted

front

--

--

not permitted

rear

--

--

0-0-0-0

75

rear

0-0-0-0

not permitted

55

over 55 t

front

I - II - III - IV in %

Telescope status

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Position of the MWL

Counterweight in t

Boom extension, light, 2,3 + 23 m 20°

82

20

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1), 2)

Gantry masts folded in or out

10.12.2014

3)

à Information about the tables, p. 6 - 5

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 13

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

45

55

set down or raised 3)

35

Superstructure position1) front

--

--

not permitted

rear

--

--

Lattice extension angle in °

not permitted

Main boom angle in °

front

I - II - III - IV in %

Telescope status

25

rear

0-0-0-0

25

42

front

17,0

22,5

0-0-0-0

82

42

rear

10,5

25,5

0-0-0-0

15

42

front

14,5

26,0

0-0-0-0

82

42

rear

13,5

26,5

front

--

--

rear

16,0

27,5

front

--

--

rear

--

--

not permitted 0-0-0-0

82

42

not permitted 75 not permitted over 55 t

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Position of the MWL

Counterweight in t

Boom extension, light, 20,3 + 5 m 42°

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 14

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

Boom extension, light, 2,3 + 11 m 42°

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

I - II - III - IV in %

Main boom angle in °

Lattice extension angle in °

Superstructure position1)

0-0-0-0

20

42

front

9,5

20,5

0-0-0-0

82

42

rear

9,5

20,5

44 - 44 - 0 - 0

50

42

front

9,5

23,0

0-0-0-0

82

42

rear

12,0

22,0

44 - 44 - 44 - 44

47

42

front

12,5

24,5

0-0-0-0

82

42

rear

14,5

23,0

88 - 44 - 44 - 44

47

42

front

14,5

25,5

0-0-0-0

82

42

rear

17,0

24,0

front

--

--

rear

22,5

26,5

Telescope status

front

25

35

45

55

not permitted

75 over 75 t

Axle load 2) in t

Driving with rigged truck crane without Mega Wing Lift

Counterweight in t

6.5.2

0-0-0-0

82

42

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 15

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

I - II - III - IV in %

Main boom angle in °

Lattice extension angle in °

Superstructure position1)

front

0-0-0-0

15

20

front

10,0

20,5

0-0-0-0

82

20

rear

10,0

20,5

44 - 0 - 0 - 0

25

20

front

13,0

21,5

0-0-0-0

82

20

rear

12,5

21,5

44 - 44 - 44 - 0

30

20

front

17,0

22,0

0-0-0-0

82

20

rear

15,0

23,0

44 - 44 - 44 - 44

25

20

front

18,0

24,0

0-0-0-0

82

20

rear

17,5

24,0

front

--

--

rear

23,0

26,5

25

35

45

55

not permitted

75 over 75 t

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 11 m 20°

0-0-0-0

82

20

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 16

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

I - II - III - IV in %

Main boom angle in °

Lattice extension angle in °

Superstructure position1)

front

0-0-0-0

25

42

front

9,5

20,5

0-0-0-0

82

42

rear

9,5

20,5

44 - 44 - 44 - 0

50

42

front

12,5

21,5

0-0-0-0

82

42

rear

12,0

22,0

44 - 44 - 44 - 0

50

42

front

11,0

25,0

0-0-0-0

82

42

rear

15,0

23,0

88 - 44 - 44 - 44

45

42

front

16,0

25,0

0-0-0-0

82

42

rear

17,5

24,0

front

--

--

rear

22,5

26,5

25

35

45

55

not permitted

75 over 75 t

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 8,3 + 5 m 42°

0-0-0-0

82

42

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 17

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

45

55

Axle load 2) in t

Superstructure position1)

25

Lattice extension angle in °

0-0-0-0

front

rear

42

front

10,5

20,0

rear

--

--

not permitted 44 - 44 - 0 - 0

50

42

front

11,5

22,5

0-0-0-0

82

42

rear

11,0

22,5

44 - 44 - 44 - 44

50

42

front

13,0

24,0

0-0-0-0

82

42

rear

13,5

23,5

88 - 44 - 44 - 44

50

42

front

15,0

25,5

0-0-0-0

82

42

rear

16,0

25,0

front

--

--

rear

21,5

27,5

not permitted

75 over 75 t

Main boom angle in °

25

35

I - II - III - IV in %

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 17 m 42°

0-0-0-0

82

42

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 18

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

I - II - III - IV in %

Main boom angle in °

Lattice extension angle in °

Superstructure position1)

front

0-0-0-0

15

20

front

11,5

19,5

0-0-0-0

82

20

rear

9,0

21,0

44 - 0 - 0 - 0

25

20

front

15,0

20,5

0-0-0-0

82

20

rear

12,0

22,0

44 - 44 - 44 - 0

30

20

front

19,5

21,0

0-0-0-0

82

20

rear

14,5

23,5

44 - 44 - 44 - 44

25

20

front

20,5

22,5

0-0-0-0

82

20

rear

17,0

24,5

88 - 44 - 44 - 44

25

20

front

21,0

27,5

0-0-0-0

82

20

rear

22,0

27,0

25

35

45

55

75 over 75 t

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 17 m 20°

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 19

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

I - II - III - IV in %

Main boom angle in °

Lattice extension angle in °

Superstructure position1)

front

0-0-0-0

25

42

front

11,5

19,5

0-0-0-0

82

42

rear

8,5

21,0

44 - 44 - 0 - 0

50

42

front

12,0

22,0

0-0-0-0

82

42

rear

11,0

22,5

44 - 44 - 44 - 0

50

42

front

11,0

25,0

0-0-0-0

82

42

rear

14,0

23,5

44 - 44 - 44 - 44

45

42

front

13,0

26,5

0-0-0-0

82

42

rear

16,5

25,0

front

--

--

rear

21,5

27,0

25

35

45

55

not permitted

75 over 75 t

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 14,3 + 5 m 42°

0-0-0-0

82

42

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 20

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

45

55

front

rear

42

front

12,5

19,5

rear

--

--

not permitted 44 - 44 - 0 - 0

50

42

front

14,0

21,5

0-0-0-0

82

42

rear

9,5

23,5

44 - 44 - 44 - 0

50

42

front

13,0

24,0

0-0-0-0

82

42

rear

12,5

24,5

88 - 44 - 44 - 44

50

42

front

17,5

24,5

0-0-0-0

82

42

rear

15,0

25,5

not permitted

front

--

--

not permitted

rear

--

--

75 over 55 t

Axle load 2) in t

30

Superstructure position1)

0-0-0-0

Lattice extension angle in °

Main boom angle in °

25

35

I - II - III - IV in %

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 23 m 42°

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 21

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

45

55

75 over 75 t

Axle load 2) in t

15

Superstructure position1)

0-0-0-0

Lattice extension angle in °

Main boom angle in °

25

35

I - II - III - IV in %

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 23 m 20°

front

rear

20

front

14,0

18,5

rear

--

--

not permitted 44 - 0 - 0 - 0

25

20

front

17,5

19,5

0-0-0-0

82

20

rear

11,0

22,5

44 - 44 - 44 - 0

30

20

front

22,0

19,5

0-0-0-0

82

20

rear

13,5

24,0

44 - 44 - 44 - 44

25

20

front

23,5

21,5

0-0-0-0

82

20

rear

16,0

25,0

88 - 44 - 44 - 44

25

20

front

24,5

26,0

0-0-0-0

82

20

rear

21,5

27,5

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 22

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

45

55

44 - 0 - 0 - 0

Axle load 2) in t

Superstructure position1)

25

Lattice extension angle in °

0-0-0-0

front

rear

42

front

14,5

18,5

rear

--

--

front

10,5

23,0

rear

--

--

not permitted 50

42

not permitted 44 - 44 - 0 - 0

30

42

front

13,5

24,0

0-0-0-0

82

42

rear

13,0

24,5

44 - 44 - 44 - 44

25

42

front

12,5

27,0

0-0-0-0

82

42

rear

15,5

25,5

front

--

--

rear

20,5

28,0

not permitted

75 over 75 t

Main boom angle in °

25

35

I - II - III - IV in %

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 20,3 + 5 m 42°

0-0-0-0

82

42

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Notes on the tables, p. 1 - 1

10.12.2014

,

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 23

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

45

55

rear

42

front

16,0

18,0

rear

--

--

front

12,0

22,5

rear

--

--

50

42

not permitted 44 - 44 - 44 - 0

50

42

front

16,0

23,0

0-0-0-0

82

42

rear

11,0

25,5

44 - 44 - 44 - 44

50

42

front

15,0

26,0

0-0-0-0

82

42

rear

14,0

26,5

not permitted

front

--

--

not permitted

rear

--

--

75 over 55 t

front

not permitted 44 - 0 - 0 - 0

Axle load 2) in t

50

Superstructure position1)

Main boom angle in °

44 - 0 - 0 - 0

Lattice extension angle in °

35

I - II - III - IV in %

25

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 29 m 42°

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 55 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 24

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

35

45

55

75 over 75 t

Axle load 2) in t

45

Superstructure position1)

Main boom angle in °

44 - 0 - 0 - 0

Lattice extension angle in °

I - II - III - IV in %

25

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 29 m 20°

front

rear

20

front

17,0

17,5

rear

--

--

not permitted 44 - 0 - 0 - 0

25

20

front

20,0

18,5

0-0-0-0

82

20

rear

10,0

23,5

44 - 44 - 0 - 0

30

20

front

21,0

20,5

0-0-0-0

82

20

rear

13,0

24,5

44 - 44 - 44 - 44

35

20

front

23,0

22,0

0-0-0-0

82

20

rear

15,0

25,5

88 - 44 - 44 - 44

30

20

front

26,0

25,5

0-0-0-0

82

20

rear

21,0

28,0

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 25

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

45

55

rear

42

front

16,5

17,5

rear

--

--

front

13,0

22,0

rear

--

--

50

42

not permitted 44 - 44 - 44 - 0

50

42

front

17,0

22,5

0-0-0-0

82

42

rear

11,5

25,0

44 - 44 - 44 - 44

50

42

front

16,0

25,5

0-0-0-0

82

42

rear

14,0

26,5

front

--

--

rear

19,0

28,5

not permitted

75 over 75 t

front

not permitted 44 - 0 - 0 - 0

Axle load 2) in t

50

Superstructure position1)

Main boom angle in °

44 - 0 - 0 - 0

Lattice extension angle in °

35

I - II - III - IV in %

25

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 26,3 + 5 m 42°

0-0-0-0

82

42

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 26

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

35

45

55

75 over 75 t

front

--

--

not permitted

rear

--

--

front

15,0

21,0

rear

--

--

front

16,0

23,5

rear

--

--

44 - 0 - 0 - 0

Lattice extension angle in °

not permitted

Main boom angle in °

front

I - II - III - IV in %

Superstructure position1)

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 35 m 42°

50

42

not permitted 44 - 44 - 0 - 0

50

42

not permitted

rear

44 - 44 - 44 - 44

50

42

front

18,0

24,5

0-0-0-0

82

42

rear

12,0

27,5

88 - 44 - 44 - 44

45

42

front

21,0

28,5

rear

--

--

not permitted

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 27

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

35

45

55

75 over 75 t

front

--

--

not permitted

rear

--

--

front

14,0

21,5

rear

--

--

44 - 0 - 0 - 0

Lattice extension angle in °

not permitted

Main boom angle in °

front

I - II - III - IV in %

Superstructure position1)

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 35 m 20°

50

20

not permitted

rear

44 - 44 - 0 - 0

40

20

front

20,0

21,5

0-0-0-0

82

20

rear

12,0

25,5

44 - 44 - 44 - 44

40

20

front

24,0

22,0

0-0-0-0

82

20

rear

14,0

26,5

88 - 44 - 44 - 44

40

20

front

23,0

27,0

rear

--

--

not permitted

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 28

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

55

75 over 75 t

--

--

not permitted

rear

--

--

front

10,0

23,5

rear

--

--

front

16,5

23,0

rear

--

--

Lattice extension angle in °

front

Main boom angle in °

not permitted

I - II - III - IV in %

front

0-0-0-0

35

45

Superstructure position1)

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 32,3 + 5 m 42°

50

42

not permitted 44 - 44 - 0 - 0

50

42

not permitted

rear

44 - 44 - 0 - 0

50

42

front

13,0

27,0

0-0-0-0

82

42

rear

12,5

27,0

88 - 44 - 44 - 44

45

42

front

21,5

27,5

rear

--

--

not permitted

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 29

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

35

45

55

75 over 75 t

front

--

--

not permitted

rear

--

--

not permitted

front

--

--

not permitted

rear

--

--

front

14,0

24,5

rear

--

--

front

15,0

26,0

rear

--

--

front

23,0

27,5

rear

--

--

44 - 0 - 0 - 0

Lattice extension angle in °

not permitted

Main boom angle in °

front

I - II - III - IV in %

Superstructure position1)

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 41 m 42°

50

42

nicht erlaubt 44 - 44 - 0 - 0

50

42

not permitted 88 - 44 - 44 - 44

47

42

not permitted

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 30

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

35

45

55

75 over 75 t

front

--

--

not permitted

rear

--

--

not permitted

front

--

--

not permitted

rear

--

--

front

20,0

21,5

rear

--

--

44 - 0 - 0 - 0

Lattice extension angle in °

not permitted

Main boom angle in °

front

I - II - III - IV in %

Superstructure position1)

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 2,3 + 41 m 20°

35

20

not permitted

rear

44 - 44 - 0 - 0

35

20

front

22,0

23,0

0-0-0-0

82

20

rear

13,0

27,5

44 - 44 - 44 - 44

30

20

front

25,0

26,0

rear

--

--

not permitted

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

Operating instructions Boom extension, light GMK 6400

3 113 164 en

6 - 31

Driving with a rigged truck crane 6.5 Tables with boom positions and axle loads

35

45

55

75 over 75 t

front

--

--

nicht erlaubt

rear

--

--

nicht erlaubt

front

--

--

nicht erlaubt

rear

--

--

front

15,0

23,5

rear

--

--

front

16,0

25,5

rear

--

--

front

25,5

26,0

rear

--

--

44 - 0 - 0 - 0

Lattice extension angle in °

nicht erlaubt

Main boom angle in °

front

I - II - III - IV in %

Superstructure position1)

25

Axle load 2) in t

All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg .

Telescope status

Counterweight in t

Boom extension, light, 38,3 + 5 m 42°

50

42

nicht erlaubt 44 - 44 - 0 - 0

50

42

nicht erlaubt 88 - 44 - 44 - 44

45

42

nicht erlaubt

rear

Driving with rigged truck crane not permissible.

Unrig the counterweight combination to 75 t.

1) 2)

à Information about the tables, p. 6 - 5

10.12.2014

,

6 - 32

3 113 164 en

Operating instructions Boom extension, light GMK 6400

7 Malfunctions

7.1

Notes on troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

1

7.2

Troubleshooting and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

3

7.2.1

Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

3

7.3

RCL malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

5

7.3.1 7.3.2

Table of lattice extension error codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Checking RCL supply lines and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

5 7

10.12.2014

7

Operating instructions Boom extension, light GMK 6400

3 113 164 en

10.12.2014

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Malfunctions 7.1 Notes on troubleshooting

7

Malfunctions

7.1

Notes on troubleshooting

General instructions

The malfunctions listed in this section only relate to the lattice extension.

H What to do in the event of malfunctions

An error message during operation with the lattice extension does not mean that the root cause of the problem is in the lattice extension. Therefore, also make sure that you also observe the Malfunctions during crane operation in the GMK 6400 operating instructions.

Observe the specifications in the Malfunctions during crane operation chapter in the GMK 6400 operating instructions depending on whether the load can be set down or not set down.

Pay particular attention to the Safety instructions in this section.

G

Risk of accidents during emergency operation.

Emergency operation with the hand-held control, the emergency telescoping program or when performing crane movements through manual actuation of solenoid valves, may only be carried out by properly qualified personnel.

There are no replaceable fuses installed in the electrical units on the lattice extension.

Observe the Fuses section in the GMK 6400 operating instructions.

ECOS malfunctions

Observe the ECOS superstructure malfunctions section in the GMK 6400 operating instructions.

RCL malfunctions

Observe the Troubleshooting the RCL section in the GMK 6400 operating instructions.

10.12.2014

Fuses

Operating instructions Boom extension, light GMK 6400

3 113 164 en

7-1

Malfunctions 7.1 Notes on troubleshooting

10.12.2014

Blank page

7-2

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Malfunctions 7.2 Troubleshooting and remedies

7.2

Troubleshooting and remedies

7.2.1

Boom extension

Malfunction

Cause

Solution

Lifting limit switch switches lights up) off (lamp

The lifting limit switch on the main boom has not been locked.

Lock the lifting limit switch on the main boom; GMK 6400 operating instructions.

The lattice extension is incorrectly connected electrically.

Check the electrical connection or, if necessary, establish connection between; – head/main boom; p. 5 - 32

N

à

à

The main boom is at an impermissible angle.

Derrick the main boom to the p. 5 - 47 required angle;

à

10.12.2014

The main boom cannot be telescoped with the rigged lattice extension

Operating instructions Boom extension, light GMK 6400

3 113 164 en

7-3

Malfunctions 7.2 Troubleshooting and remedies

10.12.2014

Blank page

7-4

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Malfunctions 7.3 RCL malfunctions

7.3

RCL malfunctions Observe the Troubleshooting the RCL section in the GMK 6400 operating instructions: – General malfunctions on the RCL – Error messages in the Monitoring submenu – Displays in the Error submenu – Table of error codes – Switch off the sensor/signal generator.

• Check whether the table contains the displayed error code. If the information in the table does not help resolve the error, note the error code(s) and contact Manitowoc Crane Care.

When all errors are remedied, the lamp (1) goes out.

7.3.1 1

Table of lattice extension error codes

19

1 ... 7

1

19

8

1

20

1 ... 7

1

20

8

à

Luffing jib error in load measurement A

Check the supply line; p. 7 - 7.

If the supply line is OK, inform

Load measurement A switched off

Switch the ignition off and then on again; if error is displayed again, notify Manitowoc Crane Care

Luffing jib error in load measurement B

Check the supply line; p. 7 - 7.

If the supply line is OK, inform

Load measurement B switched off

Switch the ignition off and then on again; if error is displayed again, notify Manitowoc Crane Care

Manitowoc Crane Care

à

Manitowoc Crane Care

10.12.2014

s

Operating instructions Boom extension, light GMK 6400

3 113 164 en

7-5

Malfunctions 7.3 RCL malfunctions

5

02

4

Lattice extension inclination is too small

Raise the lattice extension

5

02

5

Lattice extension inclination is too large

Lower the lattice extension

5

02

6

Current load greater than derricking load – Lower lattice extension movement is disabled

1.

Raise the lattice extension

2.

Press button

3.

If necessary, increase the working radius using the Lower main boom movement.

10.12.2014

Y once

7-6

3 113 164 en

Operating instructions Boom extension, light GMK 6400

Malfunctions 7.3 RCL malfunctions

7.3.2

Checking RCL supply lines and connections Whenever an error message appears that indicates a sensor or signal generator is not responding anymore or that there is a line breakage or a short to frame or earth, the cause could be – a loose plug connection or – a damaged cable.

The defective sensor or signal generator is named in the error tables.

Additionally the display Error location gives an overview of the location on the truck crane where the error has occurred.

At the corresponding point, a red mark flashes (1).

The illustrations in the following sections show the location at the lattice extension and at the truck crane in more detail.

They also allow you to see whether the defective component is located e.g. in a switch box or behind a cover and which plug connections have to be checked.

• Check plug connections and inspect corresponding electrical cables outside on the main boom and lattice extension.

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s

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7-7

Malfunctions 7.3 RCL malfunctions

On the lattice extension

With the lattice extensions, the signal generators and the plug connections are located in the foot section and in the head.

1 Electrical switch box with plug connections for lattice extension angle sensor (absolute angle) 2 Cable drum with plug connection 3 Electrical switch box with plug connections 4 Measuring plate in the head

• To check the lines, follow the lines from the

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plug connections to the signal generators or vice versa.

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8 Maintenance

8.1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

2

8.2

Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

3

8.2.1 8.2.2

Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

3 3

8.3

Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

4

8.3.1 8.3.2

Lubricating the connecting and socket pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Checking the sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

4 5

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Operating instructions Boom extension, light GMK 6400

Maintenance

8

Maintenance Adhere to the following sections from the Maintenance manual GMK 6400: – General information – Safety and environmental protection – Cleaning work – Run-in regulations – Maintenance intervals.

The following restrictions and additional information apply to the sections mentioned above: – The operating hours of the lattice extension are displayed in the Operating hours submenu; GMK 6400 operating instructions

à

– Maintenance intervals are the same as in the maintenance manual, observe factors that could shorten the intervals – Run-in regulations for the lattice extensions are not provided

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– Adhere to the valid national regulations for periodic inspections.

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8-1

Maintenance 8.1 Cleaning

8.1

Cleaning

H

Follow the instructions for cleaning work with high-pressure cleaners in the GMK 6400 operating instructions.

• Before starting cleaning work, check that all the electric and hydraulic connections are covered with protective caps and that all bridging plugs are plugged in.

Overview of subassemblies easily damaged when cleaning

G

Risk of accidents from misdirected high pressure water jet.

When working with high-pressure and steam-jet cleaners, the water jet is deflected by crane parts and could spray into your face and eyes at great speed and high pressure.

Always wear a face guard when cleaning the truck crane with high-pressure and steam-jet cleaning equipment.

• During cleaning work provide protection for the electrical parts specified.

1 Switch box 2 Cable drum 3 Terminal box

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4 Measuring plate

8-2

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Operating instructions Boom extension, light GMK 6400

Maintenance 8.2 Maintenance plans

8.2

Maintenance plans

8.2.1

Maintenance plan M 1

M1

LATTICE EXTENSION maintenance work: monthly/after approx. 100 oper. hrs.

Boom extension – Lubricating the connecting and socket pins

8.2.2

Maintenance plan M 3

à p. 8 - 4

M3

LATTICE EXTENSION maintenance work: every three months/after 300 oper. hrs.

Boom extension

à p. 8 - 5

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– Checking the sheaves

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8-3

Maintenance 8.3 Maintenance work

8.3

Maintenance work

8.3.1

Lubricating the connecting and socket pins

M1

Grease, tools Lubricating grease Grease

Designation as per DIN 51502

Specification Classification

GROVE part no.

KP - L2K

DIN 51825

00554201

– Brush.

H Prerequisites

Lubricate the pins additionally after every high-pressure cleaning in order to avoid corrosion.

– Boom extension/luffing jib is rigged: During maintenance work the truck crane is secured to prevent unauthorMaintenance manual GMK 6400 ised use;

à

or: – Boom extension/luffing jib is removed; CHECKLIST: Unrigging the boom extension, light, p. 5 - 5.

à

Check the following

There are various connecting pins and socket pins on the boom extension: – Connection on the left and right on the main boom head – Connection to the intermediate sections – On the deflection sheave on the foot section – Connection of the intermediate sections – On the inclination adjustment on the angle piece.

• Check the pins for wear such as rust, deformation, broken clips, chains and pin-type keepers.

• If the pins are damaged, have them replaced by Manitowoc Crane Care or an authorised GROVE dealer or your qualified repair crew.

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• Use only authentic replacement pins.

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Operating instructions Boom extension, light GMK 6400

Maintenance 8.3 Maintenance work

Greasing

• Clean the pins.

• Lubricate the pins with a brush.

8.3.2

M3

Checking the sheaves

This section applies to all lattice extensions and the upper and lower hook block of the luffing jib.

• Check the sheaves for damage, wear, mobility and dirt.

Check the sheaves (1) on: – Head – Angle piece – Adapter.

• Clean the dirty sheaves/rope guide sheaves.

• Have damaged, worn or stiff sheaves

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replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

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8-5

Maintenance 8.3 Maintenance work

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8-6

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Operating instructions Boom extension, light GMK 6400

9 Index

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Operating instructions Boom extension, light GMK 6400

Index

9

Index The index has the following structure: The names of the parts or assemblies you are searching for are listed in alphabetical order on the far left at the beginning of the line. The following are indented under these terms: – Operations (e.g. Outrigger beam/extend) or – Sub-terms (e.g. Steering/display and operating elements) or – Sub-terms related to operations (e.g. Hydraulic system/preheat hydraulic oil)

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H

The first search word is always a noun and is followed by an operation or a sub-term.

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Index

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Index

A

Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

B

Boom extension CHECKLIST Rigging the boom extension, light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Unrigging the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 41 Operating the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 42 Possible combinations Type A and Type B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4 Possible combinations Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 Rigging Changing the lifting limit switch and anemometer . . . . . . . . . . . . . . . . . . . 5 - 29 Connections for the hydraulic lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14 Folding deflection sheaves out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25 Locking the adapter/releasing the pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17 Placing and reeving the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36 Pushing together intermediate sections . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10 Removing/installing the deflection sheave on the angle piece . . . . . . . . . 5 - 23 Replacing deflection sheave on angle piece . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24 Rigging mode of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13 Securing/releasing the hydraulic lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16 Setting the angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27 Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 Boom extension Type C Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 Boom extensions Type A and Type B Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4

C

CHECKLIST Rigging the boom extension, light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Unrigging the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

D

Driving with rigged lattice extension Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 Driving path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 Rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 Tables with axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5

F

Finding information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8

I

Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

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9-3

Index

9-4

L

Lattice extension operating manual Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Conversion table for US measuring units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9 Definition of direction references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Finding information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Notes on ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Safety instructions for working with the lattice extension . . . . . . . . . . . . . . . . . 2 - 4 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

M

Maintenance work Lubricating the pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4

O

Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 Crane control display Power unit speeds submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 RCL display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 Submenu for entering rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 Submenu for RCL monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 Short description Crane control display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 RCL display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Assembly Boom extension Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 Boom extensions Type A and Type B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4 Information on the load capacity charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Notes on assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

P

Positional references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Possible combinations Boom extension Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6

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Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

Index

Boom extensions Type A and Type B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4

Reeving options On the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 38

S

Safety instructions For working with lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12 Symbols Used ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

T

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13 Troubleshooting Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 RCL Checking supply lines and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 Truck crane Checking the horizontal alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 48

W

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

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Index

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