Grove Crane GMK 6400 Mega Wing Lift Operating Instruction Manual 3112978 - PDF DOWNLOAD

Operating Instructions Mega Wing Lift (MWL)

3 112 978 en 2013.04.25

Important note Reproductions of this document of any kind, including excerpts, even in electronic form, are not subject to the revision service of 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 This document must not be reproduced and its content must not be utilised or disclosed without express permission.

Offenders will be made liable 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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MWL operating instructions GMK 6400

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Manitowoc Crane Group Germany GmbH

Rest for rear pendant link

On the two rests (1), the guides must be turned to – position (A) for on-road driving or – position (B) for operation.

• Take the pin (3) out of the bearing point.

Some cranes can be fitted with a bolt and nut instead of the pin.

• Turn the guide (2) to position (A) or (B).

Position (A):

for on-road driving

Position (B):

for operation

• Insert the pin (3) into the bearing point and secure it with a spring cotter or or fasten the bolt in the bearing point with the nut.

• Repeat the procedure in the same way on guide (1).

• Repeat the procedure on the other side of 12.09.2013

the main boom.

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2

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Transport position of rests A and B

When rests A (1) and B (2) are removed from the rear pendant links of the MWL (Mega Wing Lift) for on-road driving, they can be stored in holders on the MWL.

Rest A Rest A (1) has been removed from the bracket (3).

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• Remove the pin (2) from rest A (1).

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1

S

Risk of damage to side cladding on carrier.

If rest A is not installed as described in the following, the side cladding on the carrier will be damaged when the MWL is set down.

On the right and left interior winch drum:

• Hang rest A (1) in the inner holder (4).

The guides (5) should point inwards. Do not hang rest A in the outer holder (3).

• Insert the pin (2) into the connecting point.

• Hang the rest on the other side in the holder.

Rest B Rest B (1) has been removed from the bracket (3).

• Remove the pins from the connecting points (2) on rest B.

• Insert the pins into the connecting points (4)

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on rest B (1) and secure them with spring cotters.

2

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Additional page GMK 6400

On the right and left interior bracing arm:

• Place rest B (1) on both holders (2) and secure it with spring cotters.

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• Hang the rest on the other side in the holders.

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4

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Assembly aid

There is an assembly aid for installation, removal and storage of the lower head sheave axle extensions (A).

It consists of: Item

Designation

Quantity

1

Rope pull

1

2

Guard tube

2

3

Ropes

4

Installation and removal

• Fasten – the rope pull to fixed point (1) and – the rope pull hook to fixed point (2) or (3).

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1

• Once you have removed the pin (4) from attachment point (2) or (3), lift the sheave (1) with the rope pull or lower it.

To install or remove extensions (1):

• Fasten the rope of the rope pull (2) to the extension (1).

• Install or remove the extension (1) as described in the operating manual.

Once the head sheave axle extensions have been removed, they can be fastened to the sheave. A guard tube prevents damage.

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Transportation and storage

2

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Additional page GMK 6400

• Clean any old grease and dirt from the extension (2).

• Grease the slide faces of the extension (2) to prevent corrosion.

• Place the guard tube (3) on top of the extension (2).

• Fasten the guard tube (3) to the extension (2) with the ropes (4) so that it cannot come loose.

To install the extension:

• Loosen the ropes (4) and remove the guard

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tube (3).

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Driving mode supplement In the Mega Wing Lift (MWL) operating manual the driving mode table is being supplemented with driving mode 2.

Driving mode

Rigging mode

2* The MWL has been completely removed

●

Both extensions have been removed from the lower head sheave axle

●

Both extensions have been removed from the main boom pivot pin The rear pendant links have been removed The rests A and B for the rear pendant links have been removed

●

* Only when 445/95 R25 tyres with aluminium rims are used

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Driving mode 1 applies for all other types of tyre.

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Blank page

2

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The following chapters are contained in these operating instructions: Overview

2

Basic safety instructions

3

For operations planning

4

Additional operating and display elements

5

Rigging and unrigging the MWL

6

Operation with the main boom and the MWL

7

Operation with boom extension and MWL

8

Operation with luffing jib and MWL

9

Operation with heavy load lattice extension and MWL

10

Errors during operation with the MWL

11

Maintenance

12

Index

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1

MWL operating instructions GMK 6400

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MWL operating instructions GMK 6400

1 1

Overview

1.1

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

1

1.2

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

1

1.3

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

2

1.4

Function of the MWL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

6

1.5

Notes about the MWL operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

8

Abbreviation used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 What do the symbols used mean? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 Definition of positional references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 How is the operating manual structured? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10 How do I find the information I need? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11

1.6

Supplementary instructions to the operating manual . . . . . . . . . . . . . . . . . . . . . 1 - 12

1.6.1 1.6.2 1.6.3 1.6.4

Addition to the driving mode table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12 Addition to the Telescoping emergency programme submenu. . . . . . . . . . . . . 1 - 12 Addition to operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13 Rigging modes for rigging at 0° to the rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15

1.7

Conversion table for US measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16

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1.5.1 1.5.2 1.5.3 1.5.4 1.5.5

MWL operating instructions GMK 6400

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MWL operating instructions 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 Operating Instructions GMK 6400 the working; Manitowoc Crane Care; sections Accidents and Branches.

à

Adhere to the regulations regarding the duty of accident notification prevalent in the country in which you are working and inform the authorities who are in-charge of the monitoring and are 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 Operating Instructions GMK 6400 in the section Information about the warranty.

MWL operating instructions GMK 6400

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1-1

Overview 1.3 Terms used

1.3

Terms used

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On the truck crane

1-2

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MWL operating instructions GMK 6400

Overview 1.3 Terms used

On the truck crane 1 – Extensions for the lower head sheave axle 2 – Hydraulic and electrical connections 3 – Front guide 4 – Rest A 5 – Rear guide 6 – Rest B 7 – Rest C 8 – Rest D 9 – Extension for the main boom pivot 10 – Rear pendant links 1) Only if additionally equipped with boom extension or luffing jib

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1-3

Overview 1.3 Terms used

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Parts on Mega Wing Lift (MWL)

1-4

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MWL operating instructions GMK 6400

Overview 1.3 Terms used

Parts on Mega Wing Lift (MWL) 1 – Locking cylinder 2 – Deflection sheaves 3 – Holding frame 4 – Slinging points 5 – Spreader 6 – Folding frame 7 – Gantry mast 8 – Rear support 9 – Rear pendant links 10 – Winch 11 – Front support 12 – Raising cylinder 13 – Swivel ram 14 – Bracing arms1) 15 – Slinging tackle

Only if additionally equipped with boom extension or luffing jib

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1)

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1-5

Overview 1.4 Function of the MWL

Function of the MWL

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1.4

1-6

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MWL operating instructions GMK 6400

Overview 1.4 Function of the MWL

The Mega Wing Lift (MWL) is a system for bracing booms.

The MWL essentially comprises pivot frames (8), gantry masts (4) and rear pendant links (9).

The MWL can be fitted independently by setting the MWL down on the carrier in the holdings with the front (7) and rear (5) support. The main boom is then set down on the pivot frame (8) and bolted in place.

The deflection sheaves (2) are connected to the gantry masts (4) with the extension of the sheave axle (1) and the rear pendant links (9). Once the gantry masts (4) are erected, a bracing is created between the main boom pivot, gantry masts and the boom head. When telescoping, the guy ropes (3) automatically follow the movement.

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To lift the load, the gantry masts are folded outwards. The fixed bracing towards the rear and the flexible bracing towards the front increases the rigidity of the main boom so that greater loads can be lifted.

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1-7

Overview 1.5 Notes about the MWL operating manual

1.5

Notes about the MWL operating manual

1.5.1

Abbreviation used This operating manual describes the load increasing system. The system is called the Mega Wing Lift, which is abbreviated to MWL (Mega Wing Lift).

1.5.2

What do the symbols used mean?

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

1.5.3

Definition of positional references

Basic rule

Directions always depend 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

Forwards always means with driver's cab leading.

Backwards always means with the rear lights on the carrier are leading.

On the superstructure The main boom head is always at the front, which means that: 2: Right

3: Rear

4: Left

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1: Front

1-8

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MWL operating instructions GMK 6400

Overview 1.5 Notes about the MWL 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: press (1) – next to the symbol Up:

General information on the operating elements

press (2) – 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 lower part of switch down

– To switch off:

Information on the display on buttons and symbols on the display screen Operating Instructions.

à

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General rules for buttons and symbols

Press top half of switch down until the lock button latches into place

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1-9

Overview 1.5 Notes about the MWL operating manual

1.5.4

How is the operating manual structured?

Chapter 1 contains an overview of the MWL. In chapter 2 contains information on the safety requirements.

Chapter 3 contains information on operations planning, such as dimensions, weight, identification and the centre of gravity of the MWL. Chapter 4 shows the overview and a brief description of the display and operating elements of the MWL. Chapter 5 describes how the MWL is rigged.

Chapter 6, chapter 7, chapter 8 and chapter 9 show how the various lattice extensions are rigged and operated with the MWL. Instructions for troubleshooting in the event of a malfunction are specified in chapter 10.

Chapter 11 describes how the MWL is maintained.

Chapter 12 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 complete description of a rigging procedure.

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 operation instructions.

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

1 - 10

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MWL operating instructions GMK 6400

Overview 1.5 Notes about the MWL operating manual

1.5.5

How do I find the information I need?

The operating manual contains the following guides for orientation.

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

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

– The Index in chapter 12 provides an alphabetic list of keywords and search terms with a reference to the relevant page in the operating manual.

à

– Cross-references are labelled with an arrow ( ) and refer to other pages in the operating manual. 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 specific information on the truck crane or look up functions of individual elements.

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You will find an example of the use of cross references in the Operating Instructions.

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1 - 11

Overview 1.6 Supplementary instructions to the operating manual

1.6

Supplementary instructions to the operating manual

1.6.1

Addition to the driving mode table For truck cranes that are supplied with the MWL, you must not only observe the specifications in the accompanying operating manual, but also the following additional points, so that the axle load of 12 t (26 500 lbs) is not exceeded during on-road driving: Driving mode

Rigging mode

1

1.6.2

The MWL has been completely removed

●

Both extensions have been removed from the lower head sheave axle

●

Both extensions have been removed from the main boom pivot

●

The rear pendant links have been removed

●

The rests on the rear pendant links have been removed

●

Addition to the Telescoping emergency programme submenu When the MWL is rigged and the Telescoping emergency programme is switched on, the winches of the MWL do not follow automatically when telescoping. You must therefore adhere to the specifications in chapter Errors during operation with the MWL; Telescoping in the emergency programme with a rigged MWL, p. 10 - 15 before use of the Telescoping emergency programme.

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à

1 - 12

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MWL operating instructions GMK 6400

Overview 1.6 Supplementary instructions to the operating manual

1.6.3

Addition to operations planning

Thresholds for the use of the main hoist

Use of the MWL makes it possible to lift heavier loads with longer boom lengths. This requires a corresponding increase in the falls of the hoist rope and more hoist rope is needed than for operation without MWL. This means that when using the main hoist (hoist rope length 380 m (1 246 ft)), you cannot reach the ground with the hook block or with the load at certain threshold ranges, with the boom in its steepest position.

In these instances, you can use the auxiliary hoist (hoist rope length 690 m (2 263 ft)) or, if the use allows it, you can make use of correspondingly longer lifting gear.

The following table provides an overview of the minimum hook heights for use of the main hoist at the threshold ranges.

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1 - 13

Overview 1.6 Supplementary instructions to the operating manual

.

Boom length

Reeving

Minimum hook height with main hoist

15,39 m (50,5 ft)

20

1 m (4 ft)

1)

21

2 m (7 ft)

20,29 m (66,6 ft)

16

2 m (7 ft)

25,19 m (82,6 ft)

12

0 m (0 ft)

14

4 m (13 ft)

10

0 m (0 ft)

11

3 m (9 ft)

12

5 m (17 ft)

13

7,5 m (25 ft)

9

1 m (4 ft)

10

5 m (17 ft)

11

8 m (26 ft)

12

10,5 m (35 ft)

8

2 m (7 ft)

9

7 m (22 ft)

10

10,5 m (34 ft)

7

2 m (6 ft)

8

7,5 m (25 ft)

9

12 m (40 ft)

6

0 m (0 ft)

7

7 m (24 ft)

8

13,5 m (43 ft)

9

18 m (58 ft)

5

6 m (0 ft)

6

9 m (18 ft)

7

6 m (43 ft)

5

1m (4 ft)

6

12m (38 ft)

30,09 m (98,7 ft)

34,99 m (114,8 ft)

39,89 m (130,9 ft)

44,79 m (147 ft)

49,69 m (163 ft)

54,59 m (179,1 ft) 60,00 m (196,6 ft)

Only with additional equipment

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1)

1 - 14

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MWL operating instructions GMK 6400

Overview 1.6 Supplementary instructions to the operating manual

1.6.4

Rigging modes for rigging at 0° to the rear For some rigging modes with a permissible slewing range of 360°, rigging is only permitted in the superstructure position 0° to the rear.

Example: Outrigger span:

8.70 x 8.50 m (28.5 x 27.9 ft)

Counterweight:

75 t

Length of the boom extension:

64 m

Angle:

3°

Permissible slewing range:

360°

RCL code:

3623

Comment on the lifting capacity table:

*) rigging can only take place in a slewing range 0° to the rear.

With these rigging modes, the RCL only switches to the rigging program if the superstructure is in position 0° to the rear. If the superstructure is in other positions, the RCL is switched off as soon as the permissible working range is left.

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G

Danger of overturning with overridden RCL Do not override the RCL when telescoping or derricking is switched off.

Bring the superstructure into the permissible working range and turn the superstructure in position 0° to the rear. In this position, the crane movements required for the rigging are released.

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1 - 15

Overview 1.7 Conversion table for US measurements

1.7

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

Multiplying 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 2013.04.25

Converting from

1 - 16

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MWL operating instructions 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

Qualifications of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

3

2.5

Safety instructions for working with the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

4

2.6

Information on transporting persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

5

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MWL operating instructions GMK 6400

Basic safety instructions 2.1 Intended use

2

Basic safety instructions In principle, the basic safety instructions apply from the Operating Instructions. The basic safety instructions as regards the MWL supplied for the truck crane have been given below.

H 2.1

Information regarding the used warnings and symbols; Instructions.

à Operating

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 observe the specifications for intended use in the 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.

Observe the inspection and maintenance requirements for the MWL 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 the improper or unauthorised use of the GMK 6400 truck crane. The user alone assumes full responsibility for any risk.

H 2.3

In addition to the following specifications, also observe the information regarding improper use in the Operating Instructions.

Organisational measures

H

In addition to the following specifications, also observe the organisational measures in the Operating Instructionsand 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 instructed personnel may carry out work on the truck crane.

Responsibilities related to crane operation, 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 commencing work. Instruct your personnel (e.g. banksmen, slingers, rigging personnel) accordingly.

Observe all safety instructions and warnings on the truck crane.

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 carrying out any welding work.

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

The crane cab must not be tilted once the rear pendant links of the MWL have been fitted.

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Only trained staff must be used when rigging the MWL.

Basic safety instructions 2.4 Qualifications of the personnel

2.4

Qualifications of the personnel

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 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.

Training courses

Manitowoc Crane Group Germany GmbH conducts general and type-specific

à Operating Instructions.

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crane operator courses and technical courses;

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2-3

Basic safety instructions 2.5 Safety instructions for working with the MWL

2.5

Safety instructions for working with the MWL The operation of GMK 6400 with the MWL 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 steps 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.

Keep all electric and hydraulic connections free from dirt. Check the connecting points for dust, foreign bodies and moisture before installation.

This also applies to protective caps and bridging plugs.

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 zone clearly and mark the zone as such.

Only use parts of equipment (counterweight sections, sections of the MWL 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.

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MWL operating instructions GMK 6400

Basic safety instructions 2.6 Information 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.

Adhere to the transport condition described for the MWL as the information is the basis for the following.

Only use the slinging tackle with the spreader which is included in the scope of delivery of the MWL. The folding frame must be opened. This is the only way to ensure that the MWL is suspended in the correct position when installed.

The crane cab must not be tilted when the MWL is installed and the main boom is set down. The cabin collides with the rear pendant link. If the windscreen is opened, be aware of any holders in the pivoting range.

The windscreen may become damaged. The same applies when the MWL is unrigged but the rear rear pendant links are still rigged up.

When unrigging, the guy rope pulleys must not be pulled into the end positions. This could damage the guy rope.

Only rig the MWL as specified. A different sequence could cause malfunctions.

Do not put the truck crane with the MWL into operation if a fault message is displayed. Do not start operation until the cause of the malfunction has been eradicated.

2.6

Information on transporting persons

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

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Basic safety instructions 2.6 Information on transporting persons

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2-6

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MWL operating instructions GMK 6400

3 For operations planning

3.1

Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

1

3.1.1 3.1.2 3.1.3

Parts on the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Additional parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mega Wing Lift (MWL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

1 2 2

3.2

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

3

3.3

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

4

3.4

Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

5

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MWL operating instructions GMK 6400

For operations planning 3.1 Dimensions and weights

3

For operations planning

3.1

Dimensions and weights

3.1.1

Parts on the truck crane

Designation

Length x width x height in m (ft)

Weight in kg (lbs)

1

Extension for the main boom pivot, each

0,25 x 0,25 x 0,4 (0,85 x 0,85 x 1,35)

50 (110)

2

Rear pendant link A, each

1,50 x 0,25 x 0,25 (5,00 x 0,85 x 0,85)

100 (220)

3

Extensions for the lower head sheave axle, each

0,30 x 0,30 x 0,55 (1,00 x 1,00 x 1,80)

40 (88)

4

Rests A, B, C, D (in a receptacle)

1,0 x 1,0 x 0,5 (3,30 x 3,30 x 1,65)

55 (122)

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Item

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3-1

For operations planning 3.1 Dimensions and weights

3.1.2

Additional parts

Item

Designation

1, 2

Slinging tackle (Lengths specified)

3 4

1)

Weight in kg (lbs)

5.30 (18.00) 4.40 (14.50)

2 x 60 (132)

Spreader

2.30 x 0.10 x 0.30 (7.60 x 0.30 x 1.00)

45 (100)

Bracing arms, each1)

1.55 x 1.10 x 0.25 (5.10 x 3.60 x 0.85)

405 (900)

Only for boom extension and luffing jib

Mega Wing Lift (MWL)

Designation

Length x width x height (m) (ft)

Weight (kg) (lbs)

MWL assembly

10.03 x 3.12 x 2.03 33.10 x 10.30 x 6.70

11 135 24 550

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3.1.3

Length x width x height in m (ft)

3-2

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For operations planning 3.2 Identification

3.2

Identification

S

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

If an MWL is for use on several truck cranes, it must be matched to the truck crane and marked with the serial number.

Have the MWL adapted by Manitowoc Crane Care only.

This prevents malfunctions and damage.

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The serial number (1) of the MWL is located at the front, on the right-hand gantry mast.

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3-3

For operations planning 3.3 Slinging points

3.3

Slinging points

G S

Danger of accidents if used improperly!

Only fit slings to the MWL at the slinging points provided. Only use the lifting gear included in the scope of delivery.

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

Risk of damage when lifting.

Never lift the MWL if the folding frame is not opened out and the spreader is not installed. The MWL will become seriously damaged.

Lifting The MWL must be in the transport condition for lifting;

à p. 3 - 6.

The two lines in the slinging tackle included in the scope of delivery are marked A and B on trailers.

• Fasten line B: – to the spreader (1) and – the spreader to the slinging points (2).

• Fasten line A: – to the slinging points (3).

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Guiding

• Fasten the guide ropes to the connection eyes (4).

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For operations planning 3.4 Transportation

3.4

Transportation Also comply with the chapter Basic safety instructions.

S G G

Risk of damage to the MWL! Use only the slinging points specified here for fastening. Always secure the MWL by tying it down with suitable belts when it is transported on a separate vehicle. This prevents the MWL from toppling 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 killing other persons.

Risk of injury Before transportation, make sure that all rear pendant links are secured; Transport condition of the MWL, p. 3 - 6. Secure the rear pendant links that are not secure.

This way you prevent the rear pendant links from falling down while driving and injuring or killing other persons.

à

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3-5

For operations planning 3.4 Transportation

Transport condition of the MWL

• Before transportation, check that the following conditions are met: Reestablish them as necessary.

– The front supports (11) have been inserted; supports, p. 5 - 35.

– The rear supports (9) have been removed; supports, p. 5 - 35.

à Pushing in/pulling out the

à Pushing in/pulling out the

– The MWL is set down on the bearings (1) and rear supports (9) – The spreader (4) is installed; p. 5 - 32.

à Installing/removing the spreader,

– The folding frame (5) has been opened out; folding frame, p. 5 - 33.

à Folding in/folding out the

– The deflection sheaves (2) are released (transport position); Connecting/detaching the deflection sheaves to/from the lower head sheave axle, p. 5 - 49.

à

– The electrical and hydraulic connections (12) have been sealed.

– The rear pendant links have been pinned to the gantry masts (7) and secured with turnbuckles on (8) and (10).

• Fasten the restraining belts for tying purposes to connection eyes (3) and (6) only.

The parts removed from the truck crane are stowed so that they are safe for road transport and protected from damage.

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For parts on the truck crane

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4 4

Additional operating and display elements

4.1

Location of the additional operating and display elements . . . . . . . . . . . . . . . . . 4 -

1

4.1.1 4.1.2 4.1.3

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

1 7 8

4.2

Function of the additional operating and display elements . . . . . . . . . . . . . . . . . 4 -

9

In the main menu and in the luffing jib submenu . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9 In the Operation-MWL submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9 In the submenu Rigging-MWL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19 On the SLI display – "Enter rigging mode" submenu . . . . . . . . . . . . . . . . . . . . . 4 - 25 On the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26

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4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

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MWL operating instructions GMK 6400

Additional operating and display elements 4.1 Location of the additional operating and display elements

4 4.1

Additional operating and display elements

Location of the additional operating and display elements If the truck crane is equipped with an MWL, there are additional operating and display elements: – On the Crane control display – On the RCL display – and on the hand-held control supplied in each case.

4.1.1

On the crane control display On the Crane control display, there are: – A new symbol in the main menu – Two new submenus – A new symbol in the Luffing jib submenu

In the main menu

In the main menu, there is an additional symbol for opening the new submenus.

1 Submenu Operation – MWL

à p. 4 - 2, Function of the button; à p. 4 - 9

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Submenu overview;

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4-1

Additional operating and display elements 4.1 Location of the additional operating and display elements

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Submenu Operation-MWL

4-2

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Additional operating and display elements 4.1 Location of the additional operating and display elements

1.1 Lock winches 1.2 Unlock winches 1.3 Display for left-hand winch locking 1.4 Display for left-hand current rope force 1.5 Display for right-hand winch locking 1.6 Display for right-hand current rope force 2.1 Bracing angle display 2.2 Current main boom angle display 2.3 Bracing angle set value display 3.1 bracing the boom system 3.2 Bracing status display 4 Emergency programme display 5.1 Fold in left-hand gantry mast 5.2 Fold out left-hand gantry mast 5.3 Display for left-hand gantry mast 6 Display MWL 7.1 Fold in right-hand gantry mast 7.2 Fold out right-hand gantry mast 7.3 Display for right-hand gantry mast 8 Submenu Rigging-MWL Submenu overview Function of the button 9 Derricking gear display 10.1 Telescoping mechanism display 10.2 Locking status display 10.3 Display for telescoping cylinder in foot section 10.4 Directional indicator for teleautomation 10.5 Entering the nominal value for teleautomation 11 Luffing jib submenu 11.1 Bracing angle display

à p. 4 - 10 à p. 4 - 10 à p. 4 - 11 à p. 4 - 9 à p. 4 - 11 à p. 4 - 9 à p. 4 - 11 à p. 4 - 11 à p. 4 - 11 à p. 4 - 12 à p. 4 - 12 à p. 4 - 16 à p. 4 - 14 à p. 4 - 13 à p. 4 - 15 à p. 4 - 15 à p. 4 - 14 à p. 4 - 13 à p. 4 - 15 à p. 4 - 4 à p. 4 - 12 à p. 4 - 16 à p. 4 - 17 à p. 4 - 16 à p. 4 - 17 à p. 4 - 17 à p. 4 - 17 à p. 4 - 17 à p. 4 - 18

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4-3

Additional operating and display elements 4.1 Location of the additional operating and display elements

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Submenu Rigging-MWL

4-4

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Additional operating and display elements 4.1 Location of the additional operating and display elements

1.1 Lock left-hand winch 1.2 Unlock left-hand winch 1.3 Display for left-hand winch locking 1.4 Display for left-hand current rope force 2.1 Lock right-hand winch 2.2 Unlock right-hand winch 2.3 Display for right-hand winch locking 2.4 Display for right-hand current rope force 3.1 Wind left-hand winch 3.2 Unwind left-hand winch 4 Emergency programme display 5.1 Wind right-hand winch 5.2 Unwind right-hand winch 6 Display for left-hand gantry mast 7 Display for right-hand gantry mast 8 submenu Operation – MWL Submenu overview Function of the button 9 Crane cab display 10.1 Set down MWL 10.2 Raise MWL 10.3 Display MWL 5°/90°

à p. 4 - 21 à p. 4 - 20 à p. 4 - 21 à p. 4 - 19 à p. 4 - 21 à p. 4 - 20 à p. 4 - 21 à p. 4 - 19 à p. 4 - 20 à p. 4 - 19 à p. 4 - 16 à p. 4 - 19 à p. 4 - 19 à p. 4 - 23 à p. 4 - 23 à p. 4 - 2 à p. 4 - 24 à p. 4 - 22 à p. 4 - 22 à p. 4 - 22 à p. 4 - 23

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4-5

Additional operating and display elements 4.1 Location of the additional operating and display elements

In the luffing jib submenu

If the truck crane has been equipped for operation with a luffing jib (additional equipment), then there is a new symbol in the Luffing jib submenu.

1 Submenu Operation – MWL

à p. 4 - 2, Function of the button; à p. 4 - 9

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Submenu overview;

4-6

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MWL operating instructions GMK 6400

Additional operating and display elements 4.1 Location of the additional operating and display elements

4.1.2

On the RCL display On the SLI display, there are: – an additional symbol in the Enter rigging mode submenu – two additional markings in the Error message submenu In the Enter rigging mode submenu 1 MWL input;

à p. 4 - 25

In the Error message submenu There are two additional markings on the Error location displays, which flash red if an error occurs: 1 Error at the load cell for the Right-hand winch 2 Error at the load cell for the Left-hand winch Further information on the corresponding Error messages error messages in the RCL; on the RCL, p. 10 - 7.

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4-7

Additional operating and display elements 4.1 Location of the additional operating and display elements

4.1.3

On the hand-held control Several buttons on the hand-held control are assigned different functions for the MWL.

1 2

à Operating Instructions Emergency operation pre-selec- à Operating Instructions

Engine control panel tion button

Two-hand control panel

4

Selector switch for rigging

5 to 9

without function

à p. 4 - 30 à p. 4 - 27

Required connections for the different movements;

à p. 4 - 26.

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H

3

4-8

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Additional operating and display elements 4.2 Function of the additional operating and display elements

4.2

Function of the additional operating and display elements

H 4.2.1

In the following sections, the only symbols shown are those that are to be found in the corresponding menu. When reference is made to pressing a button, the button which is referred to is always the one next to or under the displayed symbol.

In the main menu and in the luffing jib submenu

1

Submenu Operation – MWL The button is only active if the MWL is electrically connected. The colour of the symbol indicates whether the button is active: Symbol is light grey:

The button is not active.

Symbol in black:

The button is active.

The Operation-MWL submenu appears after pressing the button.

If the symbol is not displayed in the main menu, then the truck crane is not equipped for operation with MWL.

4.2.2

In the Operation-MWL submenu All elements described in this section can be found in the Operation-MWL submenu. To open this menu, press the button next to the 1 symbol in the main menu.

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Displays for left-hand current rope force and right-hand current rope force Shows the current force (1) in the rope on the left-hand winch and the current force (2) in the rope on the right-hand winch. The value displayed corresponds to the value measured by the load cell on the associated winch.

The value is displayed in tonnes (t), to one decimal place.

The actual force present on the lateral head sheaves is double the value displayed, due to the two-fall reeving.

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4-9

Additional operating and display elements 4.2 Function of the additional operating and display elements

F

Lock winches This is used for locking the left-hand winch and the right-hand winch.

The button next to the symbol is only active if the boom system is not braced. The colour of the symbol indicates whether the button is active: Symbol is light grey:

The button is not active.

Symbol in black:

The button is active.

When the button is pressed, both winches are locked at the same time. The procedure is carried out for as long as the button is pressed or until the Locked end position is reached on both winches.

The Locked end position is shown on the displays for Left-hand winch locking and Right-hand winch locking.

G

Unlocking winches This is used for unlocking the left-hand winch and the right-hand winch.

The button next to the symbol is only active as long as the maximum permissible rope force for the unlocking procedure has not been exceeded.

The colour of the symbol indicates whether unlocking is enabled: Symbol is light grey:

Unlocking not enabled.

The maximum permissible rope force for the unlocking procedure has been exceeded (load being lifted). The current rope force can be read on the (1) and (2) displays.

Symbol in black:

Unlocking enabled.

When the button is pressed, both winches are unlocked at the same time. To reduce stress on the locking unit, the guy rope is unwound somewhat first.

The procedure is carried out for as long as the button is pressed or until the Unlocked end position is reached on both winches.

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The Unlocked end position is shown on the displays for Left-hand winch locking and Right-hand winch locking.

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Additional operating and display elements 4.2 Function of the additional operating and display elements

Displays for left-hand winch locking and right-hand winch locking These show the current locking status (1) for the left-hand winch and the current locking status (2) for the right-hand winch.

ab ef ef cd S

– The Locked position is shown in green,

– The Unlocked position is shown in red,

– Intermediate positions are shown in yellow,

– Error statuses are detected by the crane control and indicated by a purple symbol (!) (e.g. both proximity switches indicate simultaneously).

Bracing angle display This shows whether the main boom has been derricked to the bracing angle.

The bracing angle is the angle at which it is permissible to brace the boom system with the current telescoping: Symbol green:

The main boom is located at the bracing angle.

Symbol in grey:

The main boom is not located at the bracing angle.

Displays for current main boom angle and bracing angle set value These are used to show the current and required values when derricking the main boom to the bracing angle.

The Current main boom angle display (1) shows the current main boom angle.

The Bracing angle set value (2) shows the angle to which the main boom must be derricked for bracing to be released. The displayed value is obtained from the SLI code currently entered.

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4 - 11

Additional operating and display elements 4.2 Function of the additional operating and display elements

T

Bracing the boom system Used for bracing the boom system.

The button is only active when the following prerequisites are met: – The MWL has been raised to 90°.

– The gantry masts have been folded out.

– The main boom is located at the bracing angle.

– The telescopic sections are locked.

– There is no load being lifted other than the hook block.

– The RCL code for operation with the MWL has been entered.

The colour of the symbol indicates whether the button is active: Symbol is light grey:

The button is not active.

Symbol in black:

The button is active.

After the button is pressed, the boom system is braced. The procedure is carried out for as long as the button is pressed or until the bracing procedure has been completed.

When the bracing status has come to an end, the colour of the Bracing status display changes.

R

Bracing status display Indicates whether the boom system is braced or not: Symbol green:

The boom system has been braced, the bracing procedure has been completed

Symbol in grey:

The boom system has not been braced or the bracing procedure has not yet been completed.

k

Symbol is violet:

Lights up if an error occurs during the bracing procedure and the bracing procedure was interrupted as a result.

U

Submenu Rigging – MWL When the button next to the symbol is pressed, the display switches to the In the submenu Rigging-MWL, p. 4 - 19. submenu Rigging-MWL;

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à

4 - 12

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Additional operating and display elements 4.2 Function of the additional operating and display elements

JK

Fold out left-hand gantry mast and fold out right-hand gantry mast These are used to fold out the Left-hand gantry mast and the Right-hand gantry mast. The gantry masts can only be folded out independently of each other.

The buttons next to the symbols are only active if: – The boom system is not braced and – The MWL is raised to 90° and – There is no load raised other than the hook block.

The colour of the symbol indicates whether folding out is enabled:

JK

Symbol is light grey:

The buttons are not active.

The boom system is braced or a load is being raised.

JK

Symbol in black:

The button is active.

When one of the buttons is pressed, the associated gantry mast is folded out. The procedure is carried out for as long as the button is pressed or until the Folded out end position is reached.

If the maximum permissible rope force is exceeded when the winch is unlocked, then the winch winds off automatically when the button is pressed until a permissible level of rope force is reached. The values on the Current rope force displays (1), (2) change correspondingly. Then the folding procedure begins.

The Folded out end position is shown on the displays for Left-hand gantry mast and Right-hand gantry mast.

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4 - 13

Additional operating and display elements 4.2 Function of the additional operating and display elements

HI

Fold in left-hand gantry mast and fold in right-hand gantry mast These are used to fold in the Left-hand gantry mast and the Right-hand gantry mast. The gantry masts can only be folded in independently of each other.

The buttons next to the symbols are only active if: – The boom system is not braced and – The MWL is raised to 90° and – There is no load raised other than the hook block.

The colour of the symbol indicates whether folding in is enabled:

JK

Symbol is light grey:

The buttons are not active.

The boom system is braced or a load is being raised.

HI

Symbol in black:

The button is active.

When one of the buttons is pressed, the associated gantry mast is folded in. The procedure is carried out for as long as the button is pressed or until the Folded in end position is reached.

If the maximum permissible rope force is exceeded when the winch is unlocked, then the winch winds off automatically when the button is pressed until a permissible level of rope force is reached. The values on the Current rope force displays (1), (2) change correspondingly. Then the folding procedure begins.

If the maximum permissible rope force is exceeded during the folding procedure (e.g. if the winch is locked), the movement stops and the value in the corresponding displays Current rope force (1), (2) switches to red.

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The Folded in end position is shown on the displays for Left-hand gantry mast and Right-hand gantry mast.

4 - 14

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Additional operating and display elements 4.2 Function of the additional operating and display elements

Displays for left-hand gantry mast and right-hand gantry mast These display the current settings for the left-hand gantry mast (1) the current setting for the right-hand gantry mast (2).

PQ LM NO ln

– The Folded out position is shown in green,

– Intermediate positions are shown in yellow,

– The Folded in position is shown in green,

– Error statuses are detected by the crane control and indicated by a purple symbol (!) (e.g. both proximity switches indicate simultaneously).

Display MWL Displays the various positions that are recorded when raising and setting down the MWL.

X p

– The position MWL raised to 90° is displayed in green.

– Intermediate positions are shown in yellow. In this position derricking the main boom is blocked.

– The MWL set down position is shown in green.

m

Error statuses are detected by the crane control and indicated by a purple symbol (!) (e.g. both proximity switches indicate simultaneously).

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4 - 15

Additional operating and display elements 4.2 Function of the additional operating and display elements

Locking status display The colour of the symbol indicates the locking status of the telescoping mechanism.

Green: All the conditions of the telescoping mechanism for bracing the boom system have been met: – All telescopic sections are locked.

– The telescoping cylinder is locked.

– The telescopic section in which the telescoping cylinder is located has been set down.

Red:

One or more of the prerequisites has not been met.

Emergency programme display The Emergency programme display (1) is only shown if the emergency programme Telescoping is switched on. If the Emergency programme is shown, an emergency programme for the operation of the MWL is simultaneously active. This emergency programme is only provided for unrigging in the case of an emergency and enables the operation of the MWL when the crane control monitoring is limited.

When the MWL is rigged, you also have to observe additional points when Operation with emergency protelescoping in the emergency programme; gramme switched on, p. 10 - 11.

à

Derricking gear display The background colour of the symbol (1) indicates whether the derricking gear is switched on or off: Green: on Red:

off

8 9

Lowering

Red: Green:

Blocked Released

Raising

Red: Green:

Blocked Released

Derricking is only released if the MWL is in the Raised to 90° (X) position or in the Placed under 5° (q) position. Derricking is blocked in the intermediate position (p).

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The arrows (2) indicate the direction of movement of the derricking gear.

The colour of the arrows indicates whether this movement has been released or blocked.

Additional operating and display elements 4.2 Function of the additional operating and display elements

Telescoping mechanism display The background colour of the symbol (1) indicates whether the telescoping mechanism is switched on or off: Green: on Red:

off

The arrows (2) indicate the direction of movement of the telescoping mechanism. The colour of the arrows indicates whether this movement has been released or blocked.

8 9

Extending

Red: Green:

Blocked Released

Retraction of the telescoping

Red: Green:

Blocked Released

Displays for telescoping The following displays and indicator lamps have the same functions as in the Telescoping submenu. xx.x t

xx.x t

+xx.x°

+xx.x°

1 Display for telescoping cylinder in foot section 2 Directional indicator for teleautomation 3 Entering the nominal value for teleautomation

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0

Luffing jib submenu For switching to the luffing jib submenu. The button next to the symbol is only active when a luffing jib is connected electrically. The colour of the symbol indicates whether the button is active: Symbol is light grey:

The button is not active.

Symbol in black:

The button is active.

The Luffing jib submenu appears after pressing the button.

If the symbol is not displayed at all in the main menu, then the truck crane is not equipped for operation with a luffing jib.

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4 - 17

Additional operating and display elements 4.2 Function of the additional operating and display elements

Bracing angle display When the luffing jib is switched on electrically, an additional display appears in the Operation-MWL submenu.

The Bracing angle display appears in the symbol for the Luffing jib submenu (3).

There are two different symbols: 1 The green symbol (=7°) appears if the luffing jib is positioned at a bracing angle of 7°.

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2 The red symbol (≠ 7°) appears if the luffing jib is not positioned at the bracing angle.

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Additional operating and display elements 4.2 Function of the additional operating and display elements

4.2.3

In the submenu Rigging-MWL All elements described in this section can be found in the Rigging-MWL submenu. The submenu is opened in two steps: – First press the button in the main menu next to the symbol 1.

The display switches to the Operation-MWL. – In the Operation-MWL submenu, press the button next to the symbol U.

Displays for left-hand current rope force and right-hand current rope force These show the current force (1) in the rope on the left-hand winch and the current force (2) in the rope on the right-hand winch. The value displayed corresponds to the value measured by the load cell on the associated winch.

The value is displayed in tonnes (t), to one decimal place.

The actual force present on the lateral head sheaves is double the value displayed, due to the two-fall reeving.

gh

Wind left-hand winch and wind right-hand winch These are used for winding in the left-hand winch and the right-hand winch.

The winches can be wound in independently of one another.

The buttons next to the symbols are only active when the winch in question has been unlocked. The colour of the symbol indicates whether the button is active: Symbol is light grey:

The button is not active.

Symbol in black:

The button is active.

When the button is pressed, the winch in question is wound in and the guy rope is wound onto the drum.

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Additional operating and display elements 4.2 Function of the additional operating and display elements

ij

ef

ef

Unwind left-hand winch and unwind right-hand winch These are used for unwinding the left-hand winch and the right-hand winch.

The winches can be unwound independently of one another.

The buttons next to the symbols are only active when the winch in question has been unlocked. The colour of the symbol indicates whether the button is active: Symbol is light grey:

The buttons are not active.

Symbol in black:

The button is active.

When the button is pressed, the winch in question is unwound and the guy rope is wound off the drum.

Unlock left-hand winch and unlock right-hand winch These are used for unlocking the left-hand winch and the right-hand winch.

The buttons next to the symbols are only active as long as the maximum permissible rope force for the unlocking procedure has not been exceeded.

The colour of the symbol indicates whether unlocking is enabled: Symbol is light grey:

Unlocking not enabled.

The maximum permissible rope force for the unlocking procedure has been exceeded (load being lifted).

The current rope force can be read on the (1) and (2) displays.

Symbol in black:

Unlocking enabled.

When the button is pressed, the winch in question is unlocked. To reduce stress on the locking unit, the guy rope for that winch is unwound somewhat first.

The procedure is carried out for as long as the button is pressed or until the Unlocked end position is reached for that particular winch.

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The Unlocked end position is shown on the displays for Left-hand winch locking and Right-hand winch locking.

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Additional operating and display elements 4.2 Function of the additional operating and display elements

ab

Lock left-hand winch and lock right-hand winch These are used for locking the left-hand winch and the right-hand winch.

The buttons next to the symbols are only active if the boom system is not braced. The colour of the symbol indicates whether the button is active: Symbol is light grey:

The button is not active.

Symbol in black:

The button is active.

When the button is pressed, the winch in question is locked. The procedure is carried out for as long as the button is pressed or until the Locked end position is reached for that particular winch.

The Locked end position is shown on the displays for Left-hand winch locking and Right-hand winch locking.

Displays for left-hand winch locking and right-hand winch locking These show the current locking status for the left-hand winch (1) and the current locking status for the right-hand winch (2).

– The Locked position is shown in green, – The Unlocked position is shown in red, – Intermediate positions are shown in yellow, – Error statuses are detected by the crane control and indicated by a purple symbol (!) (e.g. both proximity switches indicate simultaneously).

s

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4 - 21

Additional operating and display elements 4.2 Function of the additional operating and display elements

Z

Raise MWL Is used for raising the MWL to the 90° position. The colour of the symbol indicates whether the button is active: Symbol is light grey:

The button is not active.

Symbol in black:

The button is active.

When the button is pressed, the MWL is raised.

The procedure is carried out for as long as the button is pressed or until the Raised 90° end position is reached.

The end position Raised 90° is shown by the display MWL. Crane cab display Indicates that the crane cab is not tilted into the lowest position. If the display (1) lights up, there is a risk of the rear pendant links damaging the crane cab when setting down the MWL. If the display lights up, the function to set down the MWL an inclination of below 10° is disabled. The movement is enabled when the display (1) disappears.

The display (1) disappears when the crane cab is tilted into the lowest position.

Y

Set down MWL Is used for setting the MWL down on the basic section of the main boom.

The button is only active if both gantry masts have been folded in and the main boom is positioned at an angle of under 5°.

The colour of the symbol indicates whether the button is active: The button is not active.

Symbol in black:

he button is active.

When the button is pressed, the MWL is set down.

The movement continues until you release the button or an end position is reached.

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Symbol is light grey:

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Additional operating and display elements 4.2 Function of the additional operating and display elements

Display MWL Display (1) shows the various positions that are recorded when raising and setting down the MWL.

X p

– The position MWL raised to 90° is displayed in green, – Intermediate positions are shown in yellow,

– The MWL set down position is shown in green,

m

Error statuses are detected by the crane control and indicated by a purple symbol (!) (e.g. both proximity switches indicate simultaneously).

Displays for left-hand gantry mast and right-hand gantry mast These display the current settings for the left-hand gantry mast (1) the current setting for the right-hand gantry mast (2).

PQ LM NO ln

– The Folded out position is shown in green,

– Intermediate positions are shown in yellow,

– The Folded in position is shown in green,

– Error statuses are detected by the crane control and indicated by a purple symbol (!) (e.g. both proximity switches indicate simultaneously).

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4 - 23

Additional operating and display elements 4.2 Function of the additional operating and display elements

V

Submenu Operation – MWL When the button next to the symbol is pressed, the display switches to the In the Operation-MWL submenu, p. 4 - 9. submenu Operation-MWL;

à

Emergency programme display The Emergency programme display (1) is only shown if the emergency programme Telescoping is switched on. If the Emergency programme is shown, an emergency programme for the operation of the MWL is simultaneously active. This emergency programme is only provided for unrigging in the case of an emergency and enables the operation of the MWL when the crane control monitoring is limited.

When the MWL is rigged, you also have to observe additional points when telescoping in the emergency programme; Operation with emergency programme switched on, p. 10 - 11.

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à

4 - 24

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Additional operating and display elements 4.2 Function of the additional operating and display elements

4.2.4

On the SLI display – "Enter rigging mode" submenu Input MWL The symbol is only displayed when the RCL on the truck crane is equipped with a programme version containing operation with MWL. The button next to the displayed symbol is always active.

If the symbol is not displayed, then the truck crane is not equipped for operation with MWL. When the button next to the Input MWL symbol is pressed, operation with MWL is selected on the RCL if it is permissible for the rigging mode displayed: – If operation with MWL is not permissible, nothing changes when the button is pressed, and the symbol is still shown with a grey background.

– If operation with MWL is permissible, the symbol is shown with a green background and the Current boom system display shows the selected rigging mode, e.g. the main boom (1) with MWL.

The chapters for operating the various different boom systems contain further information for entering the rigging mode with MWL on the RCL:

à

– Operation with main boom; p. 6 - 4, – Operation with boom extension; p. 7 - 9, – Operation with luffing jib; p. 8 - 1, – Operation with heavy load lattice extension;

à

à p. 9 - 1.

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à

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4 - 25

Additional operating and display elements 4.2 Function of the additional operating and display elements

4.2.5

On the hand-held control

Connections for hand-held control

This section only describes the sockets which are provided for connecting the hand-held control. If you connect the hand-held control to another socket, the buttons have no function or may have a different function.

The following are provided for connecting the hand-held control: – The socket (1) on the right-hand side of the basic section of the main boom, – The socket (1) on the left-hand side of the basic section of the main boom.

Only certain operations can be carried out from each socket.

Socket

1

2

Enabled operations

On the lefthand socket

– Lock/unlock right-hand winch – Wind/unwind right-hand winch – Fold in right-hand gantry mast – Raise/set down gantry masts

On the righthand socket

– Lock/unlock left-hand winch – Wind/unwind left-hand winch – Fold in left-hand gantry mast – Raise/set down gantry masts

à Operating Instructions.

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To connect the hand-held control to the sockets;

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Additional operating and display elements 4.2 Function of the additional operating and display elements

Selector switch for rigging

7

For pre-selection of the function controlled for rigging the MWL. There are fifteen pre-selection buttons with indicator lamps. Seven of these selector switches have functions for the MWL. Press the corresponding button to make pre-selections. Only the buttons which are relevant to the MWL are described below.

Selector switch for folding in gantry mast For pre-selecting the function Fold in gantry mast. The only gantry mast preselected is always the one on the side where the hand-held control has also been connected.

When the button is pressed, the red LED in the button lights up and the buttons on the two-hand operating panel are set to this function; Two-hand control panel, p. 4 - 30.

à

?

Selector switch for locking/unlocking winch For pre-selecting the function for Lock/unlock winch. The only winch preselected is always the one on the side where the hand-held control has also been connected.

When the button is pressed, the red LED in the button lights up and the buttons on the two-hand operating panel are set to this function; Two-hand control panel, p. 4 - 30.

à

=

Pre-selection button for winding/unwinding winch For pre-selecting the function for Wind/unwind winch. The only winch preselected is always the one on the side where the hand-held control has also been connected.

When the button is pressed, the red LED in the button lights up and the butTwo-hand tons on the two-hand operating panel is set to this function; control panel, p. 4 - 30.

à

9

Selector switch for raising/setting down the MWL For selecting the functions raise/set down MWL. The function does is not affected by the side on which the hand-held control is connected. When the button is pressed, the red LED in the button lights up and the buttons on the two-hand operating panel is set to this function; Two-hand control panel, p. 4 - 30.

à

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No function

>+: kl

The other buttons here have no function.

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4 - 27

Additional operating and display elements 4.2 Function of the additional operating and display elements

3 >= 4

Indicator lamp for locking status This is used to display various information, depending on the pre-selection: – If the red LED in the selector switch for Lock/unlock winch is lit up or the one in the selector switch for Wind/unwind winch is lit up, then the indicator lamp shows the locking status of the pre-selected winch (either the lefthand winch or the right-hand winch): Left-hand red LED lit up:

Left-hand winch in end position Unlocked

Right-hand red LED lit up:

Right-hand winch in end position Unlocked

5

Left-hand green LED lit up: Left-hand winch in end position Locked

2 2

Both LEDs flashing in rotation:

Intermediate position: neither of the two end positions have been reached

Both LEDs flashing simultaneously:

The crane control system has detected an error (e.g. both proximity switches displaying simultaneously).

6

Right-hand green LED lit up: Right-hand winch in end position Locked

– When the red LED in the selector switch for Fold in gantry mast is lit up, the indicator lamp shows the current position of the pre-selected gantry mast (right-hand or left-hand gantry mask):

4

Left-hand red LED lit up:

Left-hand gantry mast in end position Folded out

Right-hand red LED lit up:

Right -hand gantry mast in end position Folded out

5

Left-hand green LED lit up: Left-hand gantry mast in end position Folded in

Both LEDs flashing in rotation:

Intermediate position: neither of the two end positions have been reached

Both LEDs flashing simultaneously:

The crane control system has detected an error (e.g. both proximity switches displaying simultaneously).

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2 2

Right-hand green LED lit up: Right-hand gantry mast in end position Folded in

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Additional operating and display elements 4.2 Function of the additional operating and display elements

8

– When the red LED in the selector switch Raise/set down MWL lights up, the indicator lamp monitors the position of the MWL:

5 2 4

Green diode lit up:

The MWL has been raised to 90°.

Both LEDs flashing in rotation:

The MWL is positioned between 5° and 90°.

Red diode lit up:

The procedure to set down the MWL has been interrupted in the 5° position and the movement is disabled.

After pressing the F1 button ( @ ), the movement set down MWL is enabled again.

4 2 A

Red diode lit up:

The MWL is positioned under 5°.

Both LEDs flashing simultaneously:

The crane control system has detected an error (e.g. both proximity switches displaying simultaneously).

F1 button This button is only active when red diode in the button is lit.

When the F1 button is pressed, the diode in the button goes out.

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Additional operating and display elements 4.2 Function of the additional operating and display elements

Two-hand control panel

The buttons in the two-hand operating panel are used to carry out the preselected function or move the pre-selected power unit. Two buttons must always be pressed for this purpose: – A direction button and also – A movement button.

Direction button Use the direction buttons R (1) and the direction button r (2) to pre-select the direction of movement for the pre-selected function.

Movement button Press the movement button right/up (1) or the movement button left/down (2) to start the pre-selected movement.

The speed of the movement depends on how far in you press the movement button.

You stop the movement by letting go of the movement button or the direction button.

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The following tables show which movements can be carried out with the different button combinations for the pre-selected functions.

4 - 30

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Additional operating and display elements 4.2 Function of the additional operating and display elements

Possible movements for the selector switches for rigging the MWL Button combination

Lock/unlock winch

Wind/unwind winch

Fold in gantry mast

Raising/setting down the MWL

>

<

6

8

no function

no function

no function

Locking the winch (Right-hand or lefthand winch depending on connection)

Unlocking the winch (Right-hand or lefthand winch depending on connection)

Winding the winch (Right-hand or lefthand winch depending on connection)

Fold in gantry mast (Right-hand or lefthand depending on connection)

Raising the gantry mast

no function Unwind the winch no function

Setting down the gantry mast

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(Right-hand or lefthand winch depending on connection)

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4 - 31

Additional operating and display elements 4.2 Function of the additional operating and display elements

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Blank page

4 - 32

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5 Rigging and unrigging the MWL

5.1

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

1

5.1.1 5.1.2

CHECKLIST: Rigging the MWL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CHECKLIST: Unrigging the MWL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1 7

5.2

Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11

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 5.2.18 5.2.19 5.2.20

Installing/removing the rests for the rear pendant links . . . . . . . . . . . . . . . . . . . 5 - 11 Installing/removing the extension for the lower head sheave axle . . . . . . . . . . 5 - 19 Installing/removing the extension for the main boom pivot pin . . . . . . . . . . . . 5 - 23 Installing/removing the rear pendant links A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27 Setting the MWL down on the carrier/raising the MWL . . . . . . . . . . . . . . . . . . . 5 - 30 Installing/removing the spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32 Folding in/folding out the folding frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 33 Pushing in/pulling out the supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35 Connecting/disconnecting the rear pendant links . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36 Moving the turnbuckle into the transportation/operation position . . . . . . . . . . . . 5 - 39 Greasing the peg on the holding frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 40 Establishing/disconnecting the hydraulic connections . . . . . . . . . . . . . . . . . . . . 5 - 41 Establishing/disconnecting electrical connections . . . . . . . . . . . . . . . . . . . . . . . 5 - 42 Checking the raising cylinder stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 43 Setting the main boom down in the holding frame . . . . . . . . . . . . . . . . . . . . . . 5 - 45 Locking/unlocking the MWL to/from the main boom . . . . . . . . . . . . . . . . . . . . . 5 - 46 Connecting/detaching the deflection sheaves to/from the lower head sheave axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 49 Raising/setting down the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 51 Locking/unlocking the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 54 Winding/unwinding the winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 55

5.3

Operation from the crane cab during rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 57

5.3.1 5.3.2 5.3.3 5.3.4

Raising/setting down the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 58 Locking/unlocking the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 61 Winding/unwinding the winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 63 Folding in the gantry masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 64

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Rigging and unrigging the MWL 5.1 Checklists for rigging work

5

Rigging and unrigging the MWL

5.1

Checklists for rigging work

5.1.1

CHECKLIST: Rigging the MWL

H

This checklist is not a complete set of operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. Rig the truck crane according to CHECKLIST: Rigging; Instructions.

à Operating

2. If necessary for the job planned, rig the auxiliary hoist: – either for working with the luffing jib – or due to the necessary hoist rope length; the main hoist, p. 1 - 13.

à Thresholds for the use of

3. For operation without the luffing jib, the catcher is raised when the auxOperating Instructions. iliary hoist is rigged;

à

4. Fold in the mirrors (1) to prevent damage when setting down the MWL on the carrier.

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5-1

Rigging and unrigging the MWL 5.1 Checklists for rigging work

5. Install the rests A to D on both sides of the main boom; rests, p. 5 - 11

6. Only if operation on the main boom is planned: Install the extension for the lower head sheave axle;

à Installing the

à p. 5 - 19.

Only if operation on the lattice extension is planned.

7. Install the extension for the main boom pivot;

8. Install and secure the rear pendant links A;

à p. 5 - 23.

à p. 5 - 27.

9. Sling the MWL and set it down on the carrier; – Lift the MWL from the transporting vehicle, – Pull out the rear support; p. 5 - 35.

à

à Setting down, p. 5 - 30.

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10. Set the MWL down on the carrier;

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Rigging and unrigging the MWL 5.1 Checklists for rigging work

11. Remove the slinging tackle.

Remove the spreader; p. 5 - 32.

à

12.Folding in the folding frame;

à p. 5 - 34

13. Lower the main boom until there is a gap of approx. 15 cm ( 0.5 ft) between the main boom and the holding frame. Do not set the main boom down in the holding frame.

14. Establish connections: – Establish the hydraulic connection; – establish the electrical connection;

à p. 5 - 41, à p. 5 - 42.

15. Connect the hand-held control;

à Connections for hand-held control, p. 4 - 26, à Operating Instructions.

– Connections – connecting

16. Grease the pegs on the holding frame;

à p. 5 - 40.

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5-3

Rigging and unrigging the MWL 5.1 Checklists for rigging work

17. Check whether the right and left raising cylinder are resting on the stop; if necessary set the MWL down further; p. 5 - 43.

à

18. Set the main boom down in the holding frame;

19. Lock and secure the MWL on the main boom;

20. Raise the MWL approximately 10°;

à p. 5 - 45.

à p. 5 - 46.

à p. 5 - 51.

21. Fold out the rests A and B on the right and left of the main boom; – –

à Folding out rest A, p. 5 - 13, à Folding out rest B, p. 5 - 14.

à

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22. Set down the MWL; p. 5 - 52.

The rear pendant links rest in the folded out rests A and B on both sides.

Guide the rear pendant links by hand as necessary.

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Rigging and unrigging the MWL 5.1 Checklists for rigging work

23. Connect the rear pendant links;

à p. 5 - 36.

24. Move the turnbuckle into the Operation position;

25. Raise the MWL;

à p. 5 - 40.

à p. 5 - 51.

26. Connect the deflection sheaves to the lower head sheave axle; p. 5 - 49.

à

27. Disconnect the hand-held control unit;

à Operating Instructions.

28. Gently tighten the guy rope on both sides.

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5-5

Rigging and unrigging the MWL 5.1 Checklists for rigging work

29. Enter the current rigging mode for main boom operation.

30. If necessary for the scheduled operation, reeve the hook block with the greater load bearing capacity; Operating Instructions.

à

31. Further rigging work:

à

– For operation with the MWL and the main boom; p. 6 - 1, – For operation with the MWL and the boom extension; p. 7 - 1, p. 8 - 1, – For operation with the MWL and the luffing jib; – For operation with the MWL and the heavy load lattice extension; p. 9 - 1.

à

à

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à

5-6

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Rigging and unrigging the MWL 5.1 Checklists for rigging work

5.1.2

CHECKLIST: Unrigging the MWL

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. Bring the boom system into the rigging mode required: – After operation with braced boom system; – After operation with MWL set down;

à p. 6 - 3.

à p. 6 - 19.

– After operation with an unbraced boom system and with the MWL p. 6 - 23. raised;

à

2. Enter the current rigging mode for main boom operation.

3. Prepare the truck crane for unrigging: – The installed lattice extension has been unrigged.

– The main boom has been set down in the boom rest.

– The MWL has been raised.

4. Disconnect the guy rope pulleys from the lower head sheave axle and draw them into the guides; p. 5 - 50.

à

5. Connect the hand-held control.

– Connections Connections for hand-held control, p. 4 - 26, Operating Instructions.

– connecting

à à

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5-7

Rigging and unrigging the MWL 5.1 Checklists for rigging work

à

6. Set down the MWL, reel off the guy rope as necessary; Setting down, p. 5 - 52.

Make sure that the rear pendant links fold correctly and rest on the rests. Adjust manually as necessary.

7. Move the turnbuckle into the transportation position;

8. Disconnect the rear pendant links; Disconnect rear pendant link A.

à p. 5 - 39.

à p. 5 - 37.

9. Raise the gantry masts approximately 1.5 m (5 ft);

à Raising, p. 5 - 51.

10. Fold in rests A and B; – –

à Folding in rest A, p. 5 - 15, à Folding in rest B, p. 5 - 15.

à p. 5 - 52.

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11. Set down the gantry masts;

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Rigging and unrigging the MWL 5.1 Checklists for rigging work

12. Unlock the MWL;

à p. 5 - 47.

13. Disconnect connections: – Disconnect the hydraulic connection; – Disconnect the electrical connection;

14. Disconnect the hand-held control unit;

à p. 5 - 41. à p. 5 - 42.

à Operating Instructions.

15. Attach the MWL's slinging tackle to the hook blocks.

16. Slowly raise the main boom.

17. Fold out the folding frame;

à p. 5 - 33.

18. Fasten the slinging tackle with the spreader and guide ropes.

à

– Slinging tackle and guide ropes; Slinging points, p. 3 - 4, (A) – Installation, p. 5 - 32.

– Spreader; 2013.04.25

à

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s 5-9

Rigging and unrigging the MWL 5.1 Checklists for rigging work

19. Raise the MWL. Push in the rear support;

à p. 5 - 35.

20. Set the MWL down on the transporting vehicle; of the MWL, p. 3 - 6.

à Transport condition

21. Set the main boom down in the boom rest.

22. Remove the following parts from the truck crane:

à

– Extension for the lower head sheave axle; p. 5 - 21, – Rear pendant link A; p. 5 - 29, Removing the rests, p. 5 - 16, – Remove the rests A - D; – Extension for the main boom pivot pin; Removing the extension, p. 5 - 25.

à

à

à

23. Unrig the truck crane further as per the CHECKLIST: Unrigging; Operating Instructions.

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à

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Rigging and unrigging the MWL 5.2 Rigging work

5.2

Rigging work

5.2.1

Installing/removing the rests for the rear pendant links In order for the rear pendant links to fold properly when the gantry masts are set down, there are 4 rests on each side of the main boom: 1 Rests A 2 Rests B 3 Rests C 4 Rests D

The rests have to be removed for on-road driving.

They are installed before the MWL is placed on the carrier.

Installing the rests Installing rest A

• Remove the pins (1) and (3) from the bearing points in the rest (4).

• Move the rest (4) into the mounting (2) in position B.

• Insert the pin (1) into the bearing point and secure it with as spring cotter.

• Insert the pin (3) into the bearing point and secure it with as spring cotter.

Do not fold the rest into the A position. It would become damaged when the main boom is set down in the holding frame.

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Rigging and unrigging the MWL 5.2 Rigging work

Installing rest B

• Remove the pins (1) and (3) from the bearing points in the rest (4).

• Move the rest (4) into the mounting (2) in position B.

• Insert the pin (1) into the bearing point and secure it with as spring cotter.

• Insert the pin (3) into the bearing point and secure it with as spring cotter.

Do not fold the rest into position A yet. It would become damaged when the main boom is set down in the holding frame.

Installing rest C

• Remove the pins (1) from the bearing points in the rest (2).

• Place the rest (2) in the mounting (3).

• Insert the pins (1) into the bearing points and secure them all with one spring cotter each.

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S

Risk of damage to the front window of the crane cab.

If rest C is installed, the front window collides with it when being opened and the rest may be come damaged in the process. Open the front window carefully. Do not tilt the crane cab when rest C is installed and the front window is open.

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Rigging and unrigging the MWL 5.2 Rigging work

Installing rest D

• Move the rest (4) into the mounting (1) in position B.

• Insert the pin (3) into the bearing point and secure it with as spring cotter.

• Insert the pin (2) into the bearing point and secure it with as spring cotter.

Do not fold the rest into the A position. In position A the rest blocks access to the counterweight.

Folding out the rests

The rests A, B and D are installed and folded in. Rest C cannot be folded.

Folding out rest A

• Remove the pin from the bearing point (2).

• Fold the rest (3) into the A position.

• Insert the pin in the bearing point (1) and secure it with a spring cotter.

The main boom must not be set down in the holding frame if the rest is folded out. The rest would become damaged.

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Rigging and unrigging the MWL 5.2 Rigging work

Folding out rest B

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

• Fold the rest (3) into the A position.

• Insert the pin in the bearing point (2) and secure it with a spring cotter.

The main boom must not be set down in the holding frame if the rest is folded out. The rest would become damaged.

Folding out rest D

• Pull the pin (1) out of the bearing point.

• Fold the rest (2) into position A. • Insert the pin (1) into the bearing point and

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secure it with as spring cotter.

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Rigging and unrigging the MWL 5.2 Rigging work

Folding in rests

The rests A, B and D are folded out. Rest C cannot be folded.

Folding in rest A

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

• Fold the rest (3) into position B. • Insert the pin in the bearing point (2) and secure it with a spring cotter.

Folding in rest B

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

• Fold the rest (3) into position B. • Insert the pin in the bearing point (2) and secure it with a spring cotter.

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Rigging and unrigging the MWL 5.2 Rigging work

Folding in rest D

• Pull the pin (1) out of the bearing point.

• Fold the rest (2) into position B. • Insert the pin (1) into the bearing point and secure it with as spring cotter.

Removing the rests

Removing rest A Rest A has been folded in.

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

• Remove the rest (4) from mounting (1).

• Insert the pins in the connecting points (3) and secure them with one spring cotter each.

• Set the rest down so that it is safe for trans-

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portation.

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Rigging and unrigging the MWL 5.2 Rigging work

Removing rest B Rest B has been folded in.

• Remove the pins from the connecting points (1).

• Remove the rest (4) from mounting (2).

• Insert the pins in the connecting points (3) and secure them with one spring cotter each.

• Set the rest down so that it is safe for transportation.

Removing rest C Rear pendant link A has been removed.

• Remove the pins from the connecting points (1).

• Remove the rest (4) from mounting (2).

• Insert the pins in the connecting points (3) and secure them with one spring cotter each.

• Set the rest down so that it is safe for transportation.

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Rigging and unrigging the MWL 5.2 Rigging work

Removing rest D Rear pendant link A has been removed.

• Remove the pins from the connecting points (1).

• Remove the rest (4) from mounting (2).

• Insert the pins in the connecting points (3) and secure them with one spring cotter each.

• Set the rest down so that it is safe for trans-

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portation.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.2

Installing/removing the extension for the lower head sheave axle Deflection sheaves of the guy ropes are fastened to the extensions for the head sheave axle.

The extensions have to be removed for on-road driving.

Installing an extension

You will require an auxiliary crane for installation.

• Remove the bolts (1).

• Remove the cap (2).

• Set the cap (1) and bolts (2) down so that they are safe for transportation.

• Clean any old grease and dirt from the extension (1).

• Grease the slide faces (2).

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5 - 19

Rigging and unrigging the MWL 5.2 Rigging work

• Screw the extension (1) into the head sheave axle as far as it will go.

• Turn the extension (1) 90° to the right. In the process turn the (2) raised edge into the groove (3).

• Attach the locking bar (2) to the pin (1).

• Secure the locking bar (2) with a spring cotter.

• Install the extension on the other side of

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the main boom in the same way.

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Rigging and unrigging the MWL 5.2 Rigging work

Removing the extension

You will require an auxiliary crane for removal.

The deflection sheaves for the guy ropes have been removed from the extension for the boom pivot pin.

• Unfasten the locking bar (1).

• Set the locking bar (1) down so that it are safe for transportation.

• Turn the extension (1) 90° to the left.

• Remove the extension (1) from the boom pivot pin.

• Set the extension (1) down so that it is safe for transportation and protected from damage.

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Rigging and unrigging the MWL 5.2 Rigging work

• Fasten the cap (1) with the bolts (2); tightening torque 100 Nm (73 lbf ft).

• Remove the extension on the other side of

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the main boom in the same way.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.3

Installing/removing the extension for the main boom pivot pin The rear pendant links A are fastened to the extensions for the boom pivot pin.

The extensions have to be removed for on-road driving.

Installing an extension

You will require an auxiliary crane for installation.

• Clean any old grease and dirt from the extension (1).

• Grease the slide faces (2).

• Sling the extension. Weight approximately 50 kg (110 lbs).

• Lift the extension (1) up to the level of the bore.

• Push the extension (1) into the bore as far as it will go.

• In the process turn the extension (1) so that the raised edges (2) are inserted between the locking bars (3).

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Rigging and unrigging the MWL 5.2 Rigging work

• Turn the extension (1) 90° to the right. In the process turn the raised edge (2) into the groove (3).

Install the locking bars (1) with the bolts (2); tightening torque 100 Nm (74 lbf ft).

• Install the extension on the other side of the

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superstructure in the same way.

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Rigging and unrigging the MWL 5.2 Rigging work

Removing the extension

You will require an auxiliary crane for removal.

The rear pendant links have been removed.

• Remove the bolts (1).

• Remove the locking bars (2).

• Turn the extension (1) 90° to the left. In the process turn the raised edge (2) out of the groove.

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Rigging and unrigging the MWL 5.2 Rigging work

• Pull the extension (1) out by approximately 10 cm (0.3 ft).

• Sling the extension. Weight approximately 50 kg (110 lbs).

• Pull out the extension (1) completely.

• Set the extension (1) down so that it is safe for transportation and protected from damage.

• Remove the extension on the other side of

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the superstructure in the same way.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.4

Installing/removing the rear pendant links A Rear pendant links A are the rear pendant links (1) from the boom pivot pin to the separator point of the rear pendant links above the crane cab.

Installing and securing the rear pendant links A

Requirements: – An auxiliary crane is available.

– The crane cab is tilted into the lowest position.

– The following rests for the rear pendant links must be installed and folded out: 1 Rest C

à Installing rest C, p. 5 - 12 2 Rest D

à Installing rest D, p. 5 - 13 à Folding out rest D, p. 5 - 14 Installing

• Sling the rear pendant link (1) so that it hangs in a roughly horizontal position.

• Lift the rear pendant link (1) up to the level of the extension (2) for the boom pivot pin and hold it in position.

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Rigging and unrigging the MWL 5.2 Rigging work

• (A) – Remove the cap from the extension for the boom pivot pin (3).

• Clean the slide faces on the extension for the boom pivot pin (1) and in the bearing of the rear pendant link (2).

• (B) – Push the bearing of the rear pendant link onto the extension for the boom pivot pin.

• Fasten the cap (3) with the 4 bolts (4); tightening torque 500 Nm (370 lbf ft).

Securing

• Set the rear pendant link down with the auxiliary crane on the rests (2) and (5).

• (A) – Remove the pin from the mount (3).

• Insert the pin in the bearing point (4) and secure it with a spring cotter.

• Detach the slinging tackle.

S

Risk of damage to the crane cab.

If rear pendant link A is not secured, it will fall on the crane cab when the main boom is raised. Therefore you must secure rear pendant link A if it is not connected to the rear pendant links of the MWL.

Do not tilt the crane cab any more. The crane cab collides with the rear pendant link. The crane cab display (1) only appears if the electrical connection for the MWL has been established.

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MWL operating instructions GMK 6400

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Crane cab display

Rigging and unrigging the MWL 5.2 Rigging work

Removing rear pendant link A

Requirements: – An auxiliary crane is available.

– The crane cab is tilted into the lowest position.

Removing

• Sling the rear pendant link (1) so that it hangs in a roughly horizontal position.

• Remove the pins from the rest C or (2).

• Insert the pin in the holder (3) and secure it with a spring cotter.

• Raise the rear pendant link (1).

(A) – Remove the cap (1).

(B) – Remove the rear pendant link (3) from the extension for the boom pivot pin.

• Fasten the cap (1) with the bolts (2). Tightening torque 35 Nm (25 lbf ft).

• Lift the rear pendant link (3) from the truck crane.

• Set rear pendant link A down so that it is safe for transportation and protected from damage.

• Remove rear pendant link A on the other

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side of the superstructure in the same way.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.5

Setting the MWL down on the carrier/raising the MWL When rigging, the MWL is set down in the guides on the carrier using the truck crane.

When unrigging, the MWL is lifted from the carrier.

Setting down Guides: 1

Front guide

2

Rear guide

• Check that the following conditions are met. Establish if necessary.

à

Transport condition of the MWL, – The MWL is in transport condition; p. 3 - 6.

– The slinging tackle and the guide ropes have been attached; Slinging points, p. 3 - 4.

– The rests A and B for the rear pendant links have been folded in; Folding in rests, p. 5 - 15.

à à

S

Risk of damage to the truck crane!

When you set the MWL down on the carrier, make sure that the driver's cab does not become damaged. Have somebody give you directions if you cannot see the danger area.

• Lift the MWL from the transport vehicle.

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• Carefully place the MWL in the guides on the carrier.

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Rigging and unrigging the MWL 5.2 Rigging work

Lifting

• Check that the following conditions are met. Establish if necessary.

– The guy rope pulleys have been pulled into the transport position; p. 5 - 50.

– The rear pendant links have been disconnected and secured.

– Rear pendant link A has been secured.

– The MWL has been unlocked; p. 5 - 47.

– The rests A and B for the rear pendant links have been folded in; Folding in rests, p. 5 - 15.

– The hydraulic and electrical connections have been disconnected; p. 5 - 41, p. 5 - 42.

à

à

à à à

• Carefully raise the main boom.

S

Risk of damage When the superstructure is slewed, position the main boom at a sufficiently steep angle so that the derricking cylinder does not collide with the MWL. This way you avoid damaging the truck crane or the MWL.

In order to lift the MWL from the carrier, further conditions must be met:

à

p. 5 - 32.

– The spreader must be installed; p. 5 - 33.

– The folding frame must be folded out;

S

à

Risk of damage when lifting.

Never lift the MWL if the folding frame is not folded out and the spreader is not installed. The MWL will become damaged.

• Fasten the slinging tackle and the guide ropes; à Slinging points, p. 3 - 4.

• Sling the MWL. • Carefully lift the MWL from the guides on the carrier.

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S

Risk of damage to the truck crane!

When you lift the MWL from the carrier, make sure that the driver's cab does not become damaged. Have somebody give you directions if you cannot see the danger area.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.6

S

Installing/removing the spreader Risk of damage when lifting.

Never lift the MWL if the folding frame is not folded out and the spreader is not installed. The MWL will become severely damaged.

(A) – Installation

• Remove both pins (2).

• Place the spreader (1) on the weld-on eyes (3).

• Connect the spreader (1) and the weld-on eyes (3) with the pin (2).

• Secure the pin (2) with a retaining pin.

The slinging tackle can be installed;

à p. 3 - 4.

(B) – Removal The slinging tackle has been removed.

• Remove both pins (2).

• Remove the spreader (1) from the MWL. • Insert the pin (2) into the bearing points on the spreader (1).

• Secure the pins (2) with one retaining pin each.

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• Remove the spreader (1) from the MWL.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.7

Folding in/folding out the folding frame The folding frame (1) stabilises the MWL during installation/removal and when driving with a rigged MWL.

Folding out the folding frame On the left-hand side

• (A) – Remove the pins (1) and (2) from the bearing points.

• Fold the frame (3) inwards.

• Insert the pins (1) and (2) back in the bearing points and secure them with retaining pins.

On the right side

• Fold the frame in in the same way as on the left-hand side.

On the left-hand side again

• (B) – Remove pin (1) from bearing point (5) and insert it into bearing point (4).

• Secure the pin (1) with a retaining pin.

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Rigging and unrigging the MWL 5.2 Rigging work

Folding in the folding frame On the right side

• (A) – Remove the pins (1) and (2) from the bearing points.

• Fold the frame (3) inwards.

• Insert the pin (2) back in the bearing point.

• Insert the pin (1) in the bearing point (4).

On the left-hand side

• (B) – Remove the pins (1) and (2) from the bearing points.

• Fold the frame (3) inwards.

• Insert the pins (1) and (2) back in the bearing

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points and secure them with retaining pins.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.8

Pushing in/pulling out the supports The front supports and the rear supports can be set to two lengths.

Transportation Rigging

Front support (1)

Rear support (2)

extended/withdrawn

withdrawn

extended

extended

The following passage does not make a distinction between the front and rear support. The procedure is the same for both supports.

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

(A) – Pulling out

• Pull the support out so that the bore (2) aligns with the bearing point.

(B) – Pushing in

• Push the support in so that the bore (3) aligns with the bearing point (1).

• Insert the pin in the bearing point (1) and

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secure it with a retaining pin.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.9

Connecting/disconnecting the rear pendant links The rear pendant links on the MWL and the rear pendant link A: when rigging

are connected (1),

when unrigging

are disconnected (2).

Connecting the rear pendant links

S

Risk of damage Components hanging loosely may become caught during operation or may become hitched and break off. They may fall and injury or even kill personnel.

Always fasten any loose components as specified.

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

• Pivot the rear pendant link (3) to the connecting point (2).

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

Height differences between the rear pendant link (3) and the connecting points are evened out using the clamping screw (4).

• (A) – Unfasten the retaining pin in the holder (5).

• Unfasten the clamping screw (4) at the connecting point (6).

• (B) – Pivot the clamping screw (4) into the

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holder (5) and secure it with the retaining pin.

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Rigging and unrigging the MWL 5.2 Rigging work

• Remove the pin from the connecting point (1) and insert it into holder (2).

• Secure the pin with a spring cotter.

• Connect the rear pendant links on the other side in the same way.

Disconnecting the rear pendant links

• Remove the clamping screw (3) from the holder (2).

• Connect the clamping screw (3) and the rear pendant link (1) with the shackle.

• Remove the pin at the connecting point (5).

• Pivot the rear pendant link (6) to the connecting point (4).

Height differences between the rear pendant link (6) and the connecting points are evened out using the clamping screw (3).

• Insert the pin into the connecting point (4) and secure it with a retaining pin.

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Rigging and unrigging the MWL 5.2 Rigging work

S

Risk of damage to the crane cab.

When the rear pendant links are disconnected, rear pendant link A has to be secured. If rear pendant link A is not secured, it will fall on the crane cab when the main boom is raised.

• Remove the pin from the holder (2).

• Insert the pin into the bearing point (1).

Rear pendant link A has been secured to prevent it from falling.

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• Disconnect the rear pendant links on the other side in the same way.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.10

Moving the turnbuckle into the transportation/operation position The turnbuckle holds the rear pendant links on the MWL during transportation. For operation, the rear pendant links are placed in the rests and the turnbuckle is fastened.

Operation position:

(A),

Transportation position: (B)

Transportation position

Requirements: – The MWL has been set down.

– The rear pendant links are resting in the rests.

• Unfasten the clamping screw (2) at the connecting point (3).

• Fasten the clamping screw (2) at the connecting point (1) and secure the pin with the retaining pin.

• Tighten the clamping screw (2) so that the rear pendant links (4) are raised slightly in the rests.

• Move the turnbuckle on the other side into the transportation position in the same way.

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Rigging and unrigging the MWL 5.2 Rigging work

Operation position

Requirements: – The MWL has been set down.

– The rear pendant links are resting in the rests.

• Loosen the clamping screw (2) so that the rear pendant links (4) rest in the rests.

• Unfasten the clamping screw (2) at the connecting point (1).

• Fasten the clamping screw (2) at the connecting point (3) and secure the pin with the retaining pin.

• Move the turnbuckle on the other side into the operation position in the same way.

5.2.11

Greasing the peg on the holding frame • Grease the peg (1) on the left-hand and

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right-hand side of the holding frame.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.12

Establishing/disconnecting the hydraulic connections

Establishing

Prerequisites – The main boom must be resting on the boom rest – The MWL has been set down on the carrier.

• Unfasten the locking bar (1).

• Remove the hoses (3) from the clamp (2) and (4).

• Remove the protective caps from the hoses (3) and the connections (5).

• Connect the hoses (3) to the connections (5).

Note the colour markings.

• Fold the locking bar (1) onto the clamp (2) and secure it with a cotter pin.

The hydraulic connection has now been established.

Disconnecting

• Disconnect the hoses (3) from the connections (5).

• Seal the connections (5) and the hoses (3) with the protective caps.

• Allow the hoses (3) to hang.

• Unfasten the locking bar (1).

• Place the hoses (3) in the clamp (4).

• Fold the locking bar (1) onto the clamp (2) and secure it with a cotter pin.

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The hydraulic connection has now been disconnected.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.13

Establishing/disconnecting electrical connections

Establishing

Prerequisites – The main boom must be resting on the boom rest.

– The MWL has been set down on the carrier.

You have to establish two connections.

• (A) and (B) – Remove the plug (4) from the dummy socket (1).

• Remove the dummy plug (2) from the socket (3).

• Insert the plug (4) into the socket (3).

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

The electrical connection has now been established.

Disconnecting You have to disconnect two connections.

• (A) and (B) – Remove the plug (4) from the socket (3).

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

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

• Insert the plug (4) into the dummy socket (1).

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The electrical connection has now been broken.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.14

Checking the raising cylinder stop This check is done to ensure that the position of the holding frame (1) to the gantry mast (2) is correct for setting down the main boom.

During transport the position can change due to temperature fluctuations and vibrations.

The position is adjusted at the manufacturer's.

S Inspection

Risk of damage to the MWL! When the position between the gantry mast and the holding frame changes, there may be difficulties with installing/removing or the MWL may be damaged when the main boom is set in the holding frame. In order to avoid this, the position is checked during installation.

Requirements

à p. 5 - 41, – the hydraulic connection has been established; à p. 5 - 42 and – the hand-held control is connected; à Operating Instructions.

– the electrical connection has been established;

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5 - 43

Rigging and unrigging the MWL 5.2 Rigging work

• Check to ensure that the cylinder pipe (2) of the raising cylinder is resting on the stop (1).

If the cylinder pipe is not resting on the stop: • use the hand-held control to set the MWL down to the stop; Setting down the MWL, p. 5 - 53.

à

• Likewise on the other side, check to ensure

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that the cylinder pipe is resting properly.

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MWL operating instructions GMK 6400

Rigging and unrigging the MWL 5.2 Rigging work

5.2.15

Setting the main boom down in the holding frame • Slew the superstructure forwards.

So that the superstructure can be adjusted freely:

• Do not lock the superstructure.

• Do not switch off the slewing gear.

• Do not operate the service brake.

G

Risk of crushing when setting down the main boom.

In the area of the holding frame and the main boom there is a risk of crushing (for arms and hands) when setting down. Warning any personnel in the vicinity and request them to leave the danger area.

• Carefully set down the main boom on the boom rest.

– In the process, the main boom and the holding frame should not come into contact with each other.

– The guide (2) slides over the peg (1).

• Only lower the main boom enough so that the main boom rests on the boom rest. The bore (3) then aligns with the locking pins (4).

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Do not derrick any further; do not apply pressure to the boom rest. Malfunctions when locking the MWL on the main boom would otherwise be caused.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.16

Locking/unlocking the MWL to/from the main boom Two hydraulically actuated locking pins (4) connect the main boom to the MWL: connected:

Locking pins extended

not connected:

Locking pins retracted

Extended locking pins have to be secured with the pin (3).

You use the valve (2) to determine which locking pin is actuated.

You can use the button unit (1) to extend or retract the locking pin.

Locking

Prerequisites – The main boom has been set down on the boom rest.

– The hydraulic and electrical connections have been established.

First actuate the locking pin on the left-hand side.

Actuating the locking pins

• Switch the valve (4) to the corresponding position: for the right-hand locking pin: Position A for the left-hand locking pin:

Position B

• Press the corresponding key on the right or the left on the button unit (1): To lock:

Button (2)

To unlock:

Button (3)

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Press and hold the button until the locking pin has reached the end position.

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Rigging and unrigging the MWL 5.2 Rigging work

Securing the locking pin

S

Risk of damage!

If the locking pin is not secured, it is possible that the locking pin has not been completely extended. The MWL may fall down.

Ensure that the locking pin is secured.

• Remove the pin (1) from bore (2) and insert it into bore (3) and secure it with a spring cotter.

• If the pin (1) can not be fitted into the bore (3), extend the locking pin to its end posiActuating the locking pins, p. 5 - 46. tion;

à

• Actuate the locking pin on the right-hand side in the same way:

à p. 5 - 46, à p. 5 - 47.

– actuate the locking pin; – secure the locking pin;

Unlocking

– The main boom has been set down on the boom rest.

– The hydraulic and electrical connections have been established.

First actuate the locking pin on the left-hand side.

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5 - 47

Rigging and unrigging the MWL 5.2 Rigging work

Releasing the locking pin

• Remove the pin (1) from bore (3) and insert it into bore (2) and secure it with a spring cotter.

Actuating the locking pins

• Switch the valve (4) to the corresponding position: for the right-hand locking pin: Position A for the left-hand locking pin:

Position B

• Press the corresponding key on the right or the left on the button unit (1): To lock:

Button (2)

To unlock:

Button (3)

Press and hold the button until the locking pin has reached the end position.

• Actuate the locking pin on the right-hand side in the same way:

à p. 5 - 48, à p. 5 - 48.

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– release the locking pin; – actuate the locking pin;

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MWL operating instructions GMK 6400

Rigging and unrigging the MWL 5.2 Rigging work

5.2.17

Connecting/detaching the deflection sheaves to/from the lower head sheave axle

Connecting

Prerequisite – The MWL has been raised.

– The hand-held control unit is connected.

G

Risk of accidents when winding the guy rope.

The rotating deflection sheave and the running guy rope can trap parts of the body and injure you. You must therefore keep at a distance from the roll and the rope. Have a helper help you.

• Telescope the telescope section IV approx 1.0 m (3.3 ft) (telescope status 0 – 0 – 0 – 008).

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

• Unwind the winch; à p. 5 - 55.

The deflection sheave (1) slips downwards in the guide (2).

• Continue unwinding and guide the deflection sheave (1) by the handles (2) onto the connecting point (4) on the lower head sheave axle.

In the process, have a helper help you as necessary.

• Insert the bolt (3) into the connecting point (4) and secure it with s spring cotter.

• Connect the deflection sheave to the con2013.04.25

necting point on the other side in the same way.

• Retract telescopic section IV completely.

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5 - 49

Rigging and unrigging the MWL 5.2 Rigging work

Disconnecting

G

Risk of accidents when winding the guy rope.

The rotating deflection sheave and the running guy rope can trap parts of the body and injure you. You must therefore keep at a distance from the roll and the rope. In the process, have a helper help you as necessary.

• Unwind the winch approximately 0.3 - 0.5 m (1.0 - 1.6 ft);

à p. 5 - 55.

• Hold the deflection sheave (1) by the handles (2).

In the process, have a helper help you as necessary.

• Remove the pin (3) from the connecting point (4).

• Wind the winch so that the deflection sheave (1) is drawn into the guide (2); Winding/unwinding the winches, p. 5 - 55.

à

• Stop the winch when the gap is A approximately 150 mm (0.5 ft).

• Plug the pin (3) into the connecting point (4) and secure it with a retaining pin.

• Disconnect the deflection sheave from the

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connecting point on the other side in the same way.

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Rigging and unrigging the MWL 5.2 Rigging work

5.2.18

Raising/setting down the MWL In the process the gantry masts are raised or set down.

Prerequisites

Raising

– The hydraulic and electrical connections have been established.

Establishing/disconnecting the hydraulic connections, p. 5 - 41 Establishing/disconnecting electrical connections, p. 5 - 42. p. 4 - 26.

– The hand-held control unit is connected;

à à

à

Prerequisites – The rear pendant links are connected and the clamping screw is fastened in the holder; Connecting the rear pendant links, p. 5 - 36.

à

– The turnbuckle is fastened in the operation position; p. 5 - 40.

S

à Operation position,

Risk of damage in the clamping screw is not loosened or if the tensioning screw is not unfastened.

Before you raise the MWL, make sure that the turnbuckle is fastened in the operation position and that the clamping screw is not fastened to the rear pendant links but in the holder.

This way you make sure that parts of the rear pendant links do not become damaged when raising.

On the hand-held control

• Connect the hand-held control on the side on which you wish to operate the MWL.

• Press the button (1). When the button is pressed, the lamp in the button will light up.

• Press and hold the button (2).

• Additionally, press the button (3). The MWL is raised.

The speed of movement depends on how far in you press in the button (2).

The movement continues till the end position is reached or you release one of the two buttons.

When the MWL has been raised, the corresponding lamp in the green diode (4) lights up.

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5 - 51

Rigging and unrigging the MWL 5.2 Rigging work

Setting down

Prerequisites – The deflection sheaves have been disconnected; – The boom system is not braced.

– Both gantry masts are folded in.

– The crane cab is tilted into the lowest position.

– The front window of the crane cab is closed.

S S

à p. 5 - 50.

Risk of damage if the guy ropes are not removed Before you set down the MWL, make sure that the deflection sheaves have been disconnected.

If the deflection sheaves are not disconnected, the MWL will become damaged.

Risk of damage if the front window of the crane cab is open.

If the front window is open, it is destroyed when the MWL is set down. The closing process of the front window is not monitored. Before you set down the MWL, make sure that the front window is closed.

Check whether the gantry masts are folded in If the gantry masts are not fully folded in, setting down is not enabled.

• Press the button (1). When the button is pressed, the red diode in the button will light up.

• Check whether the lamps (1) and (2) are lit up green.

If the lamps (2) and (3 ) on one side flash alternately or one of the two lamps lights up red, the end position has not yet been reached and you must make sure this is achieved.

Positioning the gantry masts in the folded in end position

• Press the switch (1) and keep it held down.

• Additionally, press the movement button (2). The gantry mast will be folded in.

The speed of movement depends on how far in you press the movement button.

• Press and hold the button until the folded in end position has been reached and both green diodes in the indicator lamp (1) light up. way. To do so, connect the hand-held control to the required socket.

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MWL operating instructions GMK 6400

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• Check that the other gantry mast is in the correct end position in the same

Rigging and unrigging the MWL 5.2 Rigging work

H

Before setting the boom down also check if the boom is at an angle smaller than 5°. Otherwise, setting down the MWL is not enabled.

Setting down the MWL

• Ensure that the crane cab is closed to the lowest position.

• Press the button (1). When the button is pressed, the red diode in the button will light up.

• Press and hold the button (3).

• Additionally, press the button (2). The MWL is set down.

The speed of movement depends on how far in you press in the button (2).

The movement continues till the end position is reached or you release one of the two buttons.

As soon as the end position MWL raised 90° is left, both diodes (4) flash alternately.

• Press and hold the button until the MWL set down end position has been

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reached and both diodes (5) light up.

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5 - 53

Rigging and unrigging the MWL 5.2 Rigging work

5.2.19

Locking/unlocking the winch In order to wind a winch, it has to be unlocked. It is locked again after winding.

Prerequisites

– The hydraulic and electrical connections have been established.

Establishing/disconnecting the hydraulic connections, p. 5 - 41 Establishing/disconnecting electrical connections, p. 5 - 42.

– The hand-held control unit is connected; p. 4 - 26.

à à

à

Locking/unlocking the winch

• Press the button (1). When the button is pressed, the red lamp in the button will light up.

• Press the switch (4) and keep it held down.

• In addition, press on of the movement buttons (2) or (3).

Locking the winch:

Movement button (2)

Unlocking the winch:

Movement button (3)

Press and hold it until the end position has been reached.

The movement continues till the end position is reached or you release one of the two buttons.

– When the other end position has been reached, respective diode lights up.

Final position locked: green lamp (6)

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Final position unlocked: red lamp (5)

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MWL operating instructions GMK 6400

Rigging and unrigging the MWL 5.2 Rigging work

5.2.20

Winding/unwinding the winches

Prerequisites

– The hydraulic and electrical connections have been established.

Establishing/disconnecting the hydraulic connections, p. 5 - 41 Establishing/disconnecting electrical connections, p. 5 - 42.

– The hand-held control unit is connected; p. 4 - 26.

à à

à

Winding/unwinding the winches

• Press the button (1). When the button is pressed, the red lamp in the button will light up.

The winch has to be unlocked for winding and unwinding.

– The lamps (4) indicate the current status.

Locked:

green lamp (2)

Unlocked:

red lamp (3)

If the winch is locked, you have to unlock it;

à p. 5 - 54.

If the winch is unlocked, you can wind or unwind.

• Press the button (1) and keep it held down.

• In addition, press one of the buttons (2) or (3).

Winding the winch:

Button (2)

Unwind the winch:

Button (3)

The speed of movement depends on how far in you press the movement button.

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The movement continues till you release one of the two buttons or until the maximum force has been reached in the guy rope.

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Rigging and unrigging the MWL 5.2 Rigging work

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Rigging and unrigging the MWL 5.3 Operation from the crane cab during rigging

5.3

Operation from the crane cab during rigging

G Prerequisites

Risk of accidents due to inability to see the working area.

When you perform movements from the crane cab when rigging the MWL, you cannot always see the working area. Have a helper give you directions.

This way you can prevent personnel from being seriously or even fatally injured.

– The hydraulic and electrical connections have been established.

Establishing/disconnecting the hydraulic connections, p. 5 - 41 Establishing/disconnecting electrical connections, p. 5 - 42.

– The hand-held control unit has been removed. The bridging plug has been connected and secured on the sockets for the hand-held control; Operating Instructions.

à à à

– The engine for crane operation is running.

Menus

• Press the button (1) repeatedly until the main menu is displayed.

• Press the button (1) once.

In the submenu Operation-MWL you can operate the following functions: – Folding in the gantry masts;

à p. 5 - 64

• Press the button (1) once.

In the submenu Rigging-MWL you can operate the following functions: – Raising the MWL; p. 5 - 58

– Setting down the MWL; p. 5 - 59

– Locking the winches; p. 5 - 61

– Unlocking the winches; p. 5 - 62

– Unwinding the winches; p. 5 - 55

– Winding the winches; p. 5 - 55

à

à

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à à

5 - 57

Rigging and unrigging the MWL 5.3 Operation from the crane cab during rigging

5.3.1

Raising/setting down the MWL

Raise MWL

Prerequisites – The rear pendant links are connected and the clamping screw is fastened in the holder; Connecting the rear pendant links, p. 5 - 36.

à

– The turnbuckle is fastened in the operation position; p. 5 - 40.

S

à Operation position,

Risk of damage in the clamping screw is not loosened or if the tensioning screw is not unfastened.

Before you raise the MWL, make sure that the turnbuckle is fastened in the operation position and that the clamping screw is not fastened to the rear pendant links but in the holder.

This way you make sure that parts of the rear pendant links do not become damaged when raising.

• Press the button (1). The MWL is raised.

• Press and hold the button (1) until the display (2) indicates the end position: – Symbol (3) in yellow: with intermediate positions.

– Symbol (4) in green: if the end position has been reached.

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As soon as the end position is reached, the movement is stopped automatically.

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Rigging and unrigging the MWL 5.3 Operation from the crane cab during rigging

Setting down the MWL

S S

Prerequisites – The deflection sheaves have been disconnected; – The boom system is not braced.

– Both gantry masts are folded in.

– The crane cab is tilted into the lowest position.

– The front window of the crane cab is closed.

à p. 5 - 50.

Risk of damage if the guy ropes are not removed Before you set down the MWL, make sure that the deflection sheaves have been disconnected.

If the deflection sheaves are not disconnected, the MWL will become damaged.

Risk of damage if the front window of the crane cab is open.

If the front window is open, it is destroyed when the MWL is set down. The closing process of the front window is not monitored. Before you set down the MWL, make sure that the front window is closed.

• Tilt the crane cab to the lowest position; à Operating Instructions GMK 6400. Display (1) must have gone out.

If the display (1) has not gone out, the setting down process is interrupted approx. 1.0 m (3.3 ft) above the crane cab.

• Tilt the crane cab to the lowest position to end the setting down process.

• Close the front window of the crane cab.

If the gantry masts are not fully folded in, setting down is not enabled.

• Check whether the displays (1) and (2) are green.

Otherwise, the symbol (3) is shown in light grey and the button is not active.

In this case, you you have to fold both gantry p. 5 - 64. masts into the end position;

à

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The symbol (3) turns black and the button is active.

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5 - 59

Rigging and unrigging the MWL 5.3 Operation from the crane cab during rigging

H

If the symbol is still shown in light grey, check whether the main boom is positioned at an angle of under 5°.

• Press and hold the button (3) until the set down setting has been achieved:

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– As soon as the MWL leaves the raised position, the symbol (1) is shown in yellow.

– When the MWL is set down, the (2) symbol is green.

– The movement is stopped automatically.

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Rigging and unrigging the MWL 5.3 Operation from the crane cab during rigging

5.3.2

Locking/unlocking the winch

Locking/unlocking the winches

You can only lock the winches when the boom system is not braced.

When the boom system is braced, the winches are always locked and the symbols are shown in grey. The buttons are not active.

Depending on which winch you wish to operate:

• Press the respective button (1) or (2).

• Press and hold the button until the corresponding display (3) or (4) shows the end position: – Symbol (5) or (6) in yellow: as long as the locking procedure is in progress, – Symbol (3) or (4) in green: when the end state locked is achieved, – Symbol (7) or (8) in purple: If an error has occurred; Troubleshooting, p. 10 - 3

à

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Rigging and unrigging the MWL 5.3 Operation from the crane cab during rigging

Unlocking winches

This section describes how to unlock the winches during rigging. For information about unlocking the winches with a braced boom system; Derricking to the bracing angle, p. 6 - 11.

à

Unlocking is only enabled when no load is being carried other than the hook block.

The symbols are otherwise shown in grey. The buttons are not active.

H

When you press the button to unlock a winch, the corresponding guy rope will be wound in slightly in order to relieve the locking unit of pressure.

Depending on which winch you wish to operate:

• Press the respective button (1) or (2).

• Press and hold the button until the corresponding display (3) or (4) shows the end position: – Symbol (5) or (6) in yellow: as long as the locking procedure is in progress, – Symbol (3) or (4) in red: when the end state unlocked is achieved, – Symbol (7) or (8) in purple: if an error has occurred; Troubleshooting, p. 10 - 3.

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à

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Rigging and unrigging the MWL 5.3 Operation from the crane cab during rigging

5.3.3

Winding/unwinding the winches You can only wind or unwind the winches when they are unlocked.

If the displays (1) and (2) shows the green symbol for the final locked position, the corresponding symbols are shown in light grey: – the symbols (3) and (5), – the symbols (4) and (6).

The buttons are not active.

• Unlock the winch which is to be wound or unwound;

à p. 5 - 55.

If the displays (1) and (2) shows the red symbol for the final unlocked position, the corresponding symbols are shown in black: – the symbols (3) and (5), – the symbols (4) and (6).

The buttons are active.

• Press the button for the required movement.

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The movement continues till you release the button or the maximum permissible rope force is reached.

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Rigging and unrigging the MWL 5.3 Operation from the crane cab during rigging

5.3.4

Folding in the gantry masts This section only describes how to fold in the bracing arms when rigging.

Other prerequisites and conditions apply for folding in or out when the main boom is raised. The tasks are described in other chapters.

H

Folding in is only enabled if the force in the guy ropes is lesser than the maximum rope force. This is generally the case when rigging.

When the submenu Rigging-MWL is open:

• Press the button (1).

The Crane control display switches to the Operation-MWL submenu.

• Press and hold the button (1) or (2) until the corresponding display (3) or (4) shows the end position: – Symbol (5) or (6) in yellow: as long as the gantry mast is not in an end position, – Symbol (5) or (6) in green: when the end state folded in is achieved, – Symbol (3) or (4) in purple: if an error has occurred; Troubleshooting, p. 10 - 3.

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à

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MWL operating instructions GMK 6400

6 6

Operation with the main boom and the MWL

6.1

Operation with braced boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

2

CHECKLIST: Putting the boom system into the operating condition . . . . . . . . 6 - 2 CHECKLIST: Putting the boom system into rigging mode . . . . . . . . . . . . . . . . . 6 - 3 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Opening the submenu Operation – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6 Telescoping with rigged MWL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7 Folding the gantry masts out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9 Bracing the boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11 Locking/unlocking the winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14

6.2

Operation with the MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17

6.2.1 6.2.2

Putting the boom system into the operating condition. . . . . . . . . . . . . . . . . . . . 6 - 17 Putting the boom system into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19

6.3

Operation with unbraced boom system and raised MWL. . . . . . . . . . . . . . . . . . . 6 - 21

6.3.1 6.3.2

Putting the boom system into the operating condition. . . . . . . . . . . . . . . . . . . . 6 - 21 Putting the boom system into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23

6.4

Driving with a rigged truck crane and rigged MWL . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25

6.4.1 6.4.2 6.4.3

Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 26 Permissible rigging modes and axle loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 26 Permissible rigging modes and axle loads with main boom . . . . . . . . . . . . . . . 6 - 27

6.5

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29

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6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8

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Operation with the main boom and the MWL

6

Operation with the main boom and the MWL

G

Risk of accidents if the safety information is ignored For operation of the main boom with MWL the warnings in the operating manual apply.

This chapter merely supplements the operating manual with additional information required when operating the main boom together with the MWL.

This chapter provides you with information on the further procedure for operation using the main boom with MWL after rigging of the MWL. Section Operation with braced boom system – The section contains all the information required for setting the RCL, telescoping with the MWL rigged, folding in and out and bracing the MWL. Section Operation with the MWL set down – The section contains all the information required to operate with the main boom when the MWL is rigged but neither raised nor braced.

Section Operation with unbraced boom system and raised MWL – The section contains all the information required to operate with the main boom when the MWL is rigged and raised, but the boom system is not braced.

Section Driving with a rigged truck crane and rigged MWL

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– The section contains the boom positions required for driving the truck crane with the MWL rigged, and the axle loads which apply in this case.

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6-1

Operation with the main boom and the MWL 6.1 Operation with braced boom system

6.1

Operation with braced boom system This section describes operation with braced boom system, which enables increased lifting capacity.

For operation: – with the MWL rigged but not raised; p. 6 - 17.

à Operation with the MWL set down,

– with the MWL raised but with the boom system not braced; with unbraced boom system and raised MWL, p. 6 - 21.

6.1.1

à Operation

CHECKLIST: Putting the boom system into the operating condition

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. Enter the current rigging mode for operation using the main boom with MWL; Setting the RCL, p. 6 - 4.

à

2. Telescope the main boom out to the telescoping required for operation Telescoping with rigged MWL, according to the lifting capacity table; p. 6 - 7.

à

3. Fold out both gantry masts;

à Folding the gantry masts out/in, p. 6 - 9.

4. Derrick the main boom to the bracing angle required and brace the Bracing the boom system, p. 6 - 11. boom system;

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à

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Operation with the main boom and the MWL 6.1 Operation with braced boom system

6.1.2

CHECKLIST: Putting the boom system into rigging mode

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. The truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal.

2. Enter the current rigging mode for operation using the main boom with MWL; Setting the RCL, p. 6 - 4.

à

3. Set down the load; other than the hook block, no load may be raised.

4. Derrick the main boom to the bracing angle; angle, p. 6 - 11.

à Derricking to the bracing

à p. 6 - 15.

6. Fold in the gantry masts; à Folding the gantry masts out/in, p. 6 - 9.

7. Retract the main boom completely; à Telescoping with rigged MWL, 5. Unlocking the winches;

p. 6 - 7.

8. Rotate the superstructure into the 180° position for unrigging and set the main boom down in the boom rest.

à CHECKLIST: Unrigging the MWL

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9. For further unrigging of the MWL; point 2 p. 5 - 7.

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6-3

Operation with the main boom and the MWL 6.1 Operation with braced boom system

6.1.3

Setting the RCL The current rigging mode for operation with the main boom is entered on the RCL. The MWL is then entered into this rigging mode.

The Enter rigging mode submenu shows the rigging mode entered, e.g.: – Counterweight combination 95 t, – Main boom operation, – Outrigger span of 8.70 x 8.50 m (28.5 x 27.9 ft), – Slewing range ±180°.

The display (3) shows the corresponding RCL code, e.g. 1700.

The display (1) shows a truck crane with main boom.

• Press the button (2) once.

The button is only active when the MWL is in the raised to 90° position:

H

If it is not permissible to operate the MWL with the rigging mode shown, there is no change on the display.

If operation with the MWL is permissible with the rigging mode shown: – the symbol (2) shown in green, – the display (1) shows a truck crane with main boom and MWL, – the display (3) indicates the corresponding RCL code for operation with MWL, e.g. 2700.

• Confirm the selected rigging mode (Press

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button (4) 2x).

6-4

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.1 Operation with braced boom system

The submenu RCL monitoring now shows the selected rigging mode with MWL. The display (1) shows the load of the rigging programme for the current rigging mode as per the lifting capacity table, e.g. 5.0 t (11 000 lbs).

The RCL only enables the increased load bearing capacities for operation with MWL when the MWL is braced.

à Error messages on

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If error messages occur; the RCL, p. 10 - 7.

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6-5

Operation with the main boom and the MWL 6.1 Operation with braced boom system

6.1.4

Opening the submenu Operation – MWL The submenu Operation-MWL contains all the operating elements you need to put the MWL into the operating condition or rigging mode.

• Press the button (1) once.

• Press the button (1) once.

• Press the button (1) once.

The Operation-MWL submenu is open.

When the submenu Rigging-MWL is open:

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• Press the button (1) once.

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.1 Operation with braced boom system

6.1.5

Telescoping with rigged MWL When telescoping with rigged MWL: – he slewing speed is limited to 70%, – high-speed mode is disabled, – the winches follow automatically.

H

G Prerequisites

When telescoping begins, and at high telescoping speeds, the rope force may fluctuate slightly at first until it settles at a constant value.

Danger due to slack rope!

When telescoping, pay attention to the guy ropes. If they sag significantly, there is a malfunction. In this case, interrupt telescoping and wind up the Winding/unwinding the winches, winch until the guy ropes are taut ( p. 5 - 55).

In this way you prevent slack rope forming on the winches.

à

The following prerequisites must be fulfilled for telescoping: – Both gantry masts are folded in. The symbols (1) and (2) are displayed in Folding the gantry masts out/in, p. 6 - 9. green;

à

– Both winches are unlocked. The displays (1) and (2) are shown in red; Locking/unlocking the winches, p. 6 - 14.

à

Telescoping

You can use either the teleautomation from the Operation-MWL submenu or manual telescoping from the Telescoping, submenu for telescoping with the MWL rigged.

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6-7

Operation with the main boom and the MWL 6.1 Operation with braced boom system

With teleautomation The buttons under the displays (2) and the displays for telescoping (1) have the same function as in the submenu Telescoping.

Manual telescoping

• If required, open the main menu ( • Press the button (1) once.

ö

).

The Telescoping submenu opens.

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Telescoping is performed in the same way as when operating without MWL.

6-8

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.1 Operation with braced boom system

6.1.6

Folding the gantry masts out/in It is only possible to lift loads if both gantry masts are folded out and the boom system is braced.

Prerequisites

Folding the gantry masts in and out is only enabled when the following prerequisites are fulfilled: – the Operation-MWL submenu is open;

à p. 6 - 6,

– the boom system is not braced, the symbol (1) is shown in grey, – the MWL is raised to 90°, the green symbol is shown on the display (2), – There is no load raised other than the hook block.

Folding in/folding out

When all the prerequisites are fulfilled, folding in and out is enabled.

The following symbols are shown in black: – Fold in the left-hand gantry mast (1), – Fold out the left-hand gantry mast (3), – Fold in the right-hand gantry mast (2), – Fold out the right-hand gantry mast (4).

The buttons are active.

As soon as any of the prerequisites fails to be fulfilled, the symbols are shown in light grey.

The buttons are not active in this case.

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6-9

Operation with the main boom and the MWL 6.1 Operation with braced boom system

• Press and hold the button for the movement required (3), (4), (5) or (8).

If the maximum permissible rope force is exceeded during the folding procedure (e.g. if the winch is locked), the movement stops and the value in the corresponding display (1), (2) is shown in red.

In this case, you must unlock the winch; Unlocking winches, p. 6 - 15. The movement is be enabled again.

à

The folding procedure starts and the symbol (9), (10) on the corresponding display (6), (7) is shown in yellow.

The value on the display (1), (2) changes accordingly.

• Press and hold the required button (3), (4), (5) or (8) until the corresponding displays (6) or (7) show the end position: – in the end position folded in: the symbols (9) and (10) in green, – in the end position folded out the symbols (11) and (12) in green.

As soon as the end position is reached, the movement is stopped automatically.

à Errors during

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If the symbol (1) or (2) is shown in purple, there is an error; operation with the MWL, p. 10 - 3.

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.1 Operation with braced boom system

6.1.7

Bracing the boom system

Prerequisites

The following conditions must be fulfilled before bracing the boom system: – the Operation-MWL submenu is open;

à p. 6 - 6,

– The MWL is raised to the 90° end position. On the display (1) the symbol is shown in green.

– All conditions of the telescoping mechanism for bracing the boom system are fulfilled (telescopic sections locked, telescoping cylinder locked, telescopic section set down).

On the display (2) the symbol is shown in green.

– The main boom is in a telescoping position which is permissible for operation with the MWL as per the Lifting capacity table.

– Both gantry masts are folded out. The symbols (1) and (2) are displayed in green.

– The corresponding RCL code for the operation planned with the MWL has been entered.

Derricking to the bracing angle

The main boom has to be raised to the bracing angle for bracing. The specific bracing angle depends on the rigging mode.

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6 - 11

Operation with the main boom and the MWL 6.1 Operation with braced boom system

Displays:

Bracing angle setpoint value, e.g. 77°

Display (4)

Current main boom angle

Display (3)

If the main boom is raised to any angle other than the bracing angle, the symbols (1) and (2) are shown in grey.

Bracing is not enabled.

• Raise the main boom to the bracing angle; e.g. 77°.

When the main boom has been raised to the bracing angle, the symbol (1) is shown in green.

Bracing

When the prerequisites stated are fulfilled and the main boom has been raised to the bracing angle, bracing is enabled.

The symbol (1) is shown in black.

• Press and hold the button (4) until the boom system has been braced.

You can follow the bracing procedure: – The winches are wound. The values in the displays (5), (6) increase until a preset rope force has been achieved.

– The winches are unwound to a certain angle, and locked (the guy ropes may now be slightly slack).

– The symbols (1) and (2) are displayed in green.

– The symbol (3) is shown in green.

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The boom system is now braced.

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.1 Operation with braced boom system

When the boom system is braced, only the unlock winches function is enabled. The symbol (3) is shown in black. The button is active.

All other functions are disabled. The symbols (1), (2) and (4) to (7) are shown in light grey.

The buttons are not active.

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The RCL now enables the increased lifting capacity and the display Maximum load (1) shows the corresponding value in accordance with the lifting capacity table.

MWL operating instructions GMK 6400

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6 - 13

Operation with the main boom and the MWL 6.1 Operation with braced boom system

6.1.8

Locking/unlocking the winches Both winches are locked and unlocked simultaneously in the Operationp. 6 - 6.

MWL submenu; open the submenu;

à

Locking winches

You can only lock the winches when the boom system is not braced.

When the boom system is braced, the symbol(1) is shown in light grey.

The button is not active.

In this case, you must unbrace the boom system. When the boom system is not braced, the symbol (1) is shown in black. The button is active. To unbrace the boom system, you have to unlock the winches; p. 6 - 15.

à

• Press and hold the button (1) until the displays (2) and (3) show the end state: – As soon as the locking procedure is in process, the symbols (4) and (5) are shown in yellow, – when the end position locked has been reached, the symbols (2) and (3) are displayed in green.

– If the symbol (6) or (7) is shown in purple, there is an error; Errors during operation with the MWL, p. 10 - 3.

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à

6 - 14

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.1 Operation with braced boom system

Unlocking winches

The winches are only enabled for unlocking with the boom system braced if the main boom is raised to the bracing angle and no load other than the Derricking to the bracing angle, p. 6 - 11. hook block is lifted;

à

Otherwise the symbol (1) is shown in grey. The button is not active.

H

When you press the button to unlock the winches, the guy ropes are first wound in slightly in order to relieve the locking units of pressure.

• Press and hold the button (1) until the displays (2) and (3) show the end state: – As soon as the locking procedure is in process, the symbols (4) and (5) are shown in yellow, – when the end position unlocked has been reached, the symbols (2) and (3) are displayed in red.

If the symbol (6) or (7) is shown in purple, there is an error; Errors during operation with the MWL, p. 10 - 3.

à

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If the boom system had previously been braced, it is now unbraced and the symbol in the display (3) is shown in grey.

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6 - 15

Operation with the main boom and the MWL 6.1 Operation with braced boom system

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6 - 16

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.2 Operation with the MWL set down

6.2

Operation with the MWL set down This section only describes operation with the main boom and the MWL set down. The boom system is not braced and the increased lifting capacity is not enabled.

For operation: – with the MWL raised and with the boom system braced; braced boom system, p. 6 - 2.

à Operation with

– with the MWL raised but with the boom system not braced; with unbraced boom system and raised MWL, p. 6 - 21.

6.2.1

à Operation

Putting the boom system into the operating condition This section assumes that the MWL has been rigged as described in the checklist Rigging the MWL for operation with MWL set down; p. 5 - 1.

à

If previously operated with the boom system braced, check that the following conditions are met.

– the deflection sheaves have been disconnected at the fastening point; Connecting/detaching the deflection sheaves to/from the lower head sheave axle, p. 5 - 49.

– the MWL has been set down; Raising/setting down the MWL, p. 5 - 51.

à

à

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6 - 17

Operation with the main boom and the MWL 6.2 Operation with the MWL set down

Setting the RCL

For operation with the MWL set down, you must enter the current rigging mode for operation with the main boom without MWL on the RCL.

• Enter the current rigging mode.

For operation with MWL set down: – the display (1) must show a truck crane without MWL and – the display (3) must show an RCL code for operation with the main boom, e.g. 1700.

• Confirm the selected rigging mode (Press button (4) 2x).

The symbol (2) is shown in grey when the MWL is set down and the button next to the symbol is not active.

The RCL now takes into account the lifting capacity tables for the RCL code displayed for operation with the main boom.

When the MWL is set down, the values specified in the lifting capacity tables are reduced.

The reduced values are shown directly on the display (1).

To calculate these values for operations planLifting capacity tables. ning

à

H

The display (1) only shows the reduced values if the MWL is connected electrically. Otherwise, the values from the lifting capacity tables are shown – however, the reduced values still apply for shut-down of the system.

à Error messages on the RCL, p. 10 - 7.

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If error messages occur;

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.2 Operation with the MWL set down

Telescoping

G

Telescoping with the MWL set down is carried out in the same way as for operation with the main boom.

Risk of damage to the deflection sheaves and guy ropes.

Make sure that the deflection sheaves are disconnected at the side fastening points and have been pulled into the guides before you telescope the main boom with the MWL set down. This way you prevent damage to the deflection sheaves or the guy ropes when telescoping.

Derricking

When the MWL is set down, derricking is only enabled if the MWL is set down so far that the symbol (1) is displayed. Otherwise derricking is disabled and the arrows (2) in the derricking gear display are shown in red.

Main boom operation

Operation of the power units when working with the main boom with the set down is the same as for working with the main boom without MWL; Operating Instructions.

6.2.2

à

Putting the boom system into rigging mode Operation of the power units when the MWL is set down is the same as for working with the main boom without MWL; Operating Instructions.

à

This section assumes the following: – the truck crane is supported with the outrigger span required for the previous operation, and is aligned horizontally and – the actual rigging mode for operation with the main boom has been entered on the RCL.

• Set down the load.

• Fully retract the main boom.

• Rotate the superstructure for unrigging into the the 180° position and set

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the main boom down in the boom rest.

For further unrigging of the MWL; point 2 p. 5 - 7.

MWL operating instructions GMK 6400

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à CHECKLIST: Unrigging the MWL

6 - 19

Operation with the main boom and the MWL 6.2 Operation with the MWL set down

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6 - 20

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.3 Operation with unbraced boom system and raised MWL

6.3

Operation with unbraced boom system and raised MWL This section only describes operation with the main boom and the MWL raised. The boom system is not braced and the increased lifting capacity is not enabled.

For operation: – with the MWL rigged but not raised; p. 6 - 17.

à Operation with the MWL set down,

– with the MWL raised and with the boom system braced; braced boom system, p. 6 - 2.

6.3.1

à Operation with

Putting the boom system into the operating condition This section assumes that the MWL has been rigged as described in the p. 5 - 1. checklist Rigging the MWL;

à

Setting the RCL

For operation with the MWL raised and the boom system not braced, you have to enter the current rigging mode for operation of the main boom with MWL on the RCL; p. 6 - 4.

à

The submenu RCL monitoring now shows the selected rigging mode with MWL. In this operating mode, the maximum permissible load is limited to the rigging program.

The Maximum load display (1) shows the load of the rigging programme for the current rigging mode as per the Lifting capacity table, e.g. 5.0 t (11 000 lbs).

Higher loads are not enabled since the boom system is not braced.

If error messages occur; à Error messages on the RCL, p. 10 - 7.

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6 - 21

Operation with the main boom and the MWL 6.3 Operation with unbraced boom system and raised MWL

Telescoping

G

For telescoping, the same prerequisites and notes apply as for telescoping with the boom system braced.

Danger due to slack rope!

When telescoping, pay attention to the guy ropes. If they sag significantly, there is a malfunction. In this case, interrupt telescoping and wind up the Winding/unwinding the winches, winch until the guy ropes are taut ( p. 5 - 55).

In this way you prevent slack rope forming on the winches.

à

When telescoping, proceed exactly as for telescoping with braced boom system; p. 6 - 7.

à

Derricking

When the MWL is set down, derricking is only enabled if the MWL is raised so far that the symbol (1) is displayed. Otherwise derricking is disabled and the arrows (2) are shown in red.

Main boom operation

Operation of the power units when operating the main boom with the MWL raised and with the boom system unbraced is performed in the same way as operation of the main boom without MWL; Operating Instructions.

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à

6 - 22

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.3 Operation with unbraced boom system and raised MWL

6.3.2

Putting the boom system into rigging mode Operation of the power units with the MWL raised and with the boom system unbraced is performed in the same way as operation of the main boom without MWL; Operating Instructions.

à

This section assumes the following: – the truck crane is supported with the outrigger span required for the previous operation, and is aligned horizontally and – the actual rigging mode for operation with the main boom has been entered on the RCL.

• Set down the load.

• Fully retract the main boom.

• Rotate the superstructure for unrigging into the the 180° position and set the main boom down in the boom rest.

à CHECKLIST: Unrigging the MWL

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For further unrigging of the MWL; point 2 p. 5 - 7.

MWL operating instructions GMK 6400

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6 - 23

Operation with the main boom and the MWL 6.3 Operation with unbraced boom system and raised MWL

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6 - 24

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.4 Driving with a rigged truck crane and rigged MWL

6.4

Driving with a rigged truck crane and rigged MWL

Risk of accidents if your view of the truck crane is partially obstructed!

While driving, always stay in visual or radio contact with a banksman who can observe the parts which you cannot see.

Risk of overturning due to superstructure slewing.

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 with packing of stable material (e.g. wooden planks).

Risk of accidents if the RCL is overridden!

Do not override the RCL. The prescribed positions in the following tables are all within permissible areas according to the Lifting capacity tables.

The truck crane operates without overload protection if the RCL is overridden.

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G G G G G G G

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, you must observe the safety instructions relating to this in the chapter Driving with rigged truck crane.

MWL operating instructions GMK 6400

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6 - 25

Operation with the main boom and the MWL 6.4 Driving with a rigged truck crane and rigged MWL

6.4.1

Driving distance The driving distance must be even. Uneven surfaces cannot be compensated with the level adjustment system.

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 with packing of stable material (e.g. wooden planks).

6.4.2

S

Permissible rigging modes and axle loads Risk of damage to the axle lines!

Bring the superstructure and the main boom into the specified positions only. This prevents excessive strain on the axle lines.

Refer to the specified sections on how you move the truck crane into the stipulated positions.

– Heavy load lattice extension:

à p. 6 - 27 à p. 7 - 26 à p. 8 - 26 à p. 9 - 22

– Auxiliary single-sheave boom top:

Not available yet

– Main boom: – Boom extension:

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– Luffing jib:

6 - 26

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.4 Driving with a rigged truck crane and rigged MWL

6.4.3

G

Permissible rigging modes and axle loads with main boom Risk of accidents if the RCL is overridden!

Do not override the RCL. The prescribed positions in the following tables are all within permissible areas according to the Lifting capacity tables.

The truck crane operates without overload protection if the RCL is overridden.

Before moving, you have to put the truck crane in the required rigging mode.

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

• Unrig the counterweight parts if necessary. It is only possible to unrig the counterweight with the truck crane itself when the MWL is set down: – Set down the MWL as necessary;

à Setting down the MWL, p. 5 - 59.

– Lower the counterweight onto the counterweight platform.

– Enter the rigging mode with 0 t counterweight for operation with main boom and without MWL on the RCL display; Setting the RCL, p. 6 - 18.

à

– Unrig the necessary counterweight parts.

– Lift the remaining counterweight onto the turntable.

– Lock the remaining counterweight on the turntable.

• Enter the RCL code for the actual rigging mode of the truck crane in accordance with the lifting capacity table: – When the MWL is set down for operation with the main boom without MWL; Setting the RCL, p. 6 - 18.

à

– When the MWL is raised for operation using the main boom with MWL; Setting the RCL, p. 6 - 4.

à

• Bring the superstructure and the main boom into the position which is stipulated in the following table for the specified counterweight rigged.

• Switch off the slewing gear; à Operating Instructions.

• Lock the superstructure; à Operating Instructions.

• Reeve larger hook blocks rather than those permitted.

Permitted hook blocks;

à Axle load tables, p. 6 - 28.

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

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6 - 27

Operation with the main boom and the MWL 6.4 Driving with a rigged truck crane and rigged MWL

Axle load tables

The specified axle loads apply for reeved 32 t hook blocks (weight 620 kg (1 370 lbs)).

Rigged counterweight in t

Position of the MWL

60

abgelegt

80

aufgerichtet (90°)

100, 120, 140, 160

Telescoping the telescopic section I/II/III/IV

Main boom angle in °

0/0/0/0

82

Data not available yet.

0/0/0/0 82

Boom position1)

Axle load2) in t (x 1000 lbs) front

rear

hinten

17,0 (37,5)

28,0 (61,8)

hinten

24,0 (53,0)

28,0 (61,8)

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 80 t abrüsten.

1)

indicated slewing angle 0°

Front:

indicated slewing angle 180°

Front:

on each the first and second axle line

Rear:

on each of the 3rd to 6th axle lines

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2)

Rear:

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MWL operating instructions GMK 6400

Operation with the main boom and the MWL 6.5 Driving

6.5

Driving

Before driving

• Check the tyre pressure and the wind speed;

à Operating Instructions.

• Check whether

à

– the slewing gear is switched off; Operating Instructions.

– the superstructure is locked; Operating Instructions.

à

• Place the truck crane on the wheels; à 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.

Driving from the driver's cab

• Engage the lowest starting gear; à 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 Operating Instructions.

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

While driving

• Drive only at the lowest possible speed, maximum 1.5 km/h (1 mph).

• The turning radius should be as large as possible when driving around corners!

• Steer the truck crane only when it is rolling and avoid sudden steering movements.

Danger of overturning when switching on the suspension!

The suspension must be deactivated (locked) as long as the rigged truck crane is on wheels.

When switching on the suspension, the suspension cylinders would suddenly be pressed together and damaged, and the truck crane could overturn.

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S G

Risk of damage to the steering linkage!

The steering linkage can be damaged if the steering is operated while the vehicle is stationary.

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6 - 29

Operation with the main boom and the MWL 6.5 Driving

After driving

• Switch the separate steering off after driving; à Operating Instructions.

• Apply the parking brake; à Operating Instructions.

Set the truck crane down on the outrigger span required for the scheduled Operating Instructions. operation;

à

If necessary, rig the counterweight sections

Before driving, unrigged counterweight sections have to be rigged again. It is only possible to rig the counterweight with the truck crane itself when the MWL is set down.

• Set down the MWL as necessary; à Setting down the MWL, p. 5 - 59.

• Lower the counterweight onto the counterweight platform.

• Enter the actual rigging mode on the RCL with 0 t (0 lbs) counterweight with the MWL set down;

à Setting the RCL, p. 6 - 18.

• Rig the necessary counterweight parts.

• Lift the counterweight onto the turntable.

• Lock the counterweight on the turntable.

• Enter the rigging mode on the RCL for the currently rigged counterweight

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with the MWL set down.

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MWL operating instructions GMK 6400

7 Operation with boom extension and MWL

7.1

Further rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

3

7.1.1 7.1.2 7.1.3

CHECKLIST: Rigging for operation with boom extension . . . . . . . . . . . . . . . . . . 7 CHECKLIST: Unrigging after operation with the boom extension . . . . . . . . . . . 7 Extra information on positioning the hoist rope with the MWL rigged . . . . . . . 7 -

3 4 5

7.2

Operation with braced boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

7

7.2.1 7.2.2 7.2.3

CHECKLIST: Putting the boom system into the operating condition . . . . . . . . 7 CHECKLIST: Putting the boom system into rigging mode . . . . . . . . . . . . . . . . . 7 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

7 8 9

7.3

Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11

7.3.1 7.3.2 7.3.3

Installing/removing the bracing arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 Folding out/folding in the bracing arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14 Shifting the deflection sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16

7.4

Operation with MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19

7.4.1 7.4.2

Putting the boom system into the operating condition. . . . . . . . . . . . . . . . . . . . 7 - 19 Putting the boom system into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21

7.5

Rigging mode with unbraced boom system and raised MWL . . . . . . . . . . . . . . . 7 - 23

7.6

Driving with rigged crane and rigged boom extension with rigged MWL . . . . . 7 - 25

7.6.1 7.6.2 7.6.3

Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 Rigging modes for moving and axle loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31

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MWL operating instructions GMK 6400

Operation with boom extension and MWL

7

Operation with boom extension and MWL

G

Risk of accidents if the safety instructions are ignored For operation with the boom extension together with the MWL, all the warnings in the lattice extension operating manual also apply.

This chapter merely supplements the lattice extension operating manual with additional information required when operating the boom extension together with the MWL. This chapter provides you with information on the further procedure for operation using the boom extension with MWL after rigging of the MWL. Section Further rigging work – The section contains information on the further rigging procedure and on preparation for rigging for operation with the boom extension and MWL. Section Operation with braced boom system – The section contains all the information required for setting the RCL, telescoping with the MWL rigged, folding in and out and bracing the boom system with boom extension.

Section Operation with MWL set down – The section contains all the information required on operation of the boom extension when the MWL is rigged but neither raised nor braced.

Section Driving with rigged crane and rigged boom extension with rigged MWL

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– The section contains the boom positions required for driving the truck crane with the MWL rigged, and the axle loads which apply in this case.

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7-1

Operation with boom extension and MWL

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7-2

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.1 Further rigging work

7.1

Further rigging work

7.1.1

CHECKLIST: Rigging for operation with boom extension

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. The MWL has been rigged as described in the chapter Rigging and unrigCHECKLIST: Rigging the MWL, p. 5 - 1. ging the MWL;

à

2. Check on the relevant lifting capacity table whether the rigging mode to be set can only be rigged with the superstructure positioned to the rear; p. 1 - 15. Turn the superstructure to the position 0° to the rear if necessary.

à

3. Rig the required boom extension as described in the lattice extension operating manual.

à

4. Fold down the bracing arm; p. 7 - 14.

Install the bracing arm beforehand as necessary;

à p. 7 - 11.

5. Shift the deflection sheaves from the lower head sheave axle onto the bracing arm; p. 7 - 16.

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à

6. Bring the boom system into the operating condition required: – For operation with braced boom system; – For operation with MWL set down;

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à p. 7 - 7,

à p. 7 - 19.

7-3

Operation with boom extension and MWL 7.1 Further rigging work

7.1.2

CHECKLIST: Unrigging after operation with the boom extension

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. Bring the boom system into the rigging mode required: – After operation with braced boom system; – After operation with MWL set down;

à p. 7 - 8,

à p. 7 - 21.

2. Enter the current rigging mode for operation with the boom extension; lattice extension operating manual.

à

3. Shift the deflection sheaves from the bracing arms onto the lower head sheave axle; p. 7 - 17.

à

à

p. 7 - 15.

4. Fold in the bracing arms; If necessary, remove the bracing arm;

à p. 7 - 12.

5. Rig the boom extension as described in the lattice extension operating lattice extension operating manual. manual;

à

à CHECKLIST: Unrigging the MWL, 2013.04.25

6. To continue unrigging the MWL; p. 5 - 7.

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.1 Further rigging work

7.1.3

Extra information on positioning the hoist rope with the MWL rigged When operating with the MWL and boom extension, only one hoist rope (either the main hoist rope or the auxiliary hoist rope) can be reeved.

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G

Risk of accidents due to overload.

Hook blocks must not be reeved on the main boom when operating with the boom extension on the braced boom system. The load is not monitored by the RCL. The truck crane may be overloaded.

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7-5

Operation with boom extension and MWL 7.1 Further rigging work

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7-6

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.2 Operation with braced boom system

7.2

Operation with braced boom system This section describes operation with the boom extension and a braced boom system, which enables increased lifting capacity.

For operation with the MWL rigged but not raised; set down, p. 7 - 19.

7.2.1

à Operation with MWL

CHECKLIST: Putting the boom system into the operating condition

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. Enter the current rigging mode for operation with the boom extension and MWL; Setting the RCL, p. 7 - 9.

à

2. Telescope the main boom to the telescope status required for operation according to the Lifting capacity table. Telescoping is performed in the same way as for operation with the main boom without boom extenTelescoping with rigged MWL, p. 6 - 7. sion;

à

3. Fold out both gantry masts. Folding out is performed in the same way as for operation with the main boom without boom extension; Folding the gantry masts out/in, p. 6 - 9.

à

4. Derrick the main boom to the bracing angle required and brace the boom system. Derricking and bracing is performed in the same way as for operation with the main boom without boom extension; Bracing the boom system, p. 6 - 11.

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à

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7-7

Operation with boom extension and MWL 7.2 Operation with braced boom system

7.2.2

CHECKLIST: Putting the boom system into rigging mode

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. The truck crane is supported with the outrigger span required for the previous operation, and aligned horizontally.

2. Enter the current rigging mode for operation with the boom extension and MWL; p. 7 - 9.

à

3. Set down the load; other than the hook block, no load may be raised.

4. Check on the relevant lifting capacity table whether the rigging mode to be set can only be rigged with the superstructure positioned to the rear; p. 1 - 15. Turn the superstructure to the position 0° to the rear if necessary.

à

5. To unlock the MWL, derrick the main boom to the bracing angle; p. 6 - 11.

à

à p. 6 - 14.

7. Fold in the gantry masts; à p. 6 - 9.

8. Retract the main boom completely; à Telescoping with rigged MWL, 6. Unlocking the winches;

p. 6 - 7.

9. Slew the superstructure into the position for unrigging the boom extension and derrick the main boom into the horizontal position.

à CHECKLIST: Unrigging after opera-

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10. To continue unrigging the MWL; tion with the boom extension, p. 7 - 4.

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.2 Operation with braced boom system

7.2.3

Setting the RCL The current rigging mode for operation with the boom extension is entered on the RCL. The MWL is then entered into this rigging mode.

The Enter rigging mode submenu shows the rigging mode entered, e.g.: – Counterweight combination 95 t, – Boom extension 24 m (79 ft), 3°, – Outrigger span of 8.70 x 8.50 m (28.5 x 27.9 ft), – Slewing range ±180°.

The display (3) shows the corresponding RCL code, e.g. 3712.

The display (1) shows a truck crane with boom extension.

• Press the button (2) once.

The button is only active when the MWL is in the raised to 90° position.

H

If it is not permissible to operate the MWL with the rigging mode shown, there is no change on the display.

If operation with the MWL is permissible with the rigging mode shown: – the symbol (2) is shown in green, – the display (1) shows a truck crane with – boom extension and MWL, – the display (3) indicates the corresponding RCL code for operation with MWL, e.g. 4712.

• Confirm the selected rigging mode (Press button (4) 2x).

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7-9

Operation with boom extension and MWL 7.2 Operation with braced boom system

The submenu RCL monitoring now shows the selected rigging mode with MWL. The display (1) shows the load of the rigging programme for the current rigging mode as per the lifting capacity table, e.g. 5.0 t (11 000 lbs).

The RCL only enables the increased load bearing capacities for operation with MWL when the MWL is braced.

à Error messages on

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If error messages occur; the RCL, p. 10 - 7.

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.3 Rigging work

7.3

Rigging work

7.3.1

Installing/removing the bracing arms For operation of the boom extension or luffing jib with MWL the bracing arms (1) have to be installed on the right and left of the foot section.

The bracing arms (1) on the foot section can remain installed for operation with the boom extension or luffing jib without MWL. The bracing arms of the foot section can be removed for transportation.

Installing

• Check whether the support (4) is pinned at the connecting point (3). The pin has to be secured with a spring cotter.

If the support is not secured:

• Fold and pin the support (4) in the connecting point (3). Secure the pin with a spring cotter.

• Sling bracing arm (1). Dimensions and weight;

à Additional parts, p. 3 - 2.

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

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7 - 11

Operation with boom extension and MWL 7.3 Rigging work

• Raise the bracing arm (1) onto the foot section so that both connecting points (2) are aligned.

• Insert the pins in both connecting points (2) and secure them with one spring cotter each.

• Secure the pin (5).

• Pivot the bracing arm (1) onto the foot section as shown.

• Insert the pin (5) and secure it with a spring cotter.

• Remove the spring cotter from the pin (4).

• Screw the connecting piece (3) onto the pin (4) as illustrated.

• Secure the connecting piece (3) by attaching the spring cotter to the pin (4).

• Install the bracing arm on the other side of the foot section in the same way.

Removing

Prerequisite The bracing arm (1) has been installed and folded in;

à Folding in, p. 7 - 15.

• Sling bracing arm (1). Dimensions and weight;

à Additional parts, p. 3 - 2.

• Secure the pin (5).

• Remove the spring cotter from the pin (4).

• Turn the connecting piece (3) so that tit hangs down.

• Remove the pins from the two connecting

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points (2).

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.3 Rigging work

• Lift the bracing arm (1) off the foot section.

• Insert both pins into the bearing points (2) on the bracing arm (1).

• Insert the pin in the bearing point (4) and secure it with a spring cotter.

• Insert the spring cotter on the pin (3).

• Set the bracing arm down so that it is safe for transportation and protected from damage.

• Remove the bracing arm on the other side

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of the foot section in the same way.

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7 - 13

Operation with boom extension and MWL 7.3 Rigging work

7.3.2

Folding out/folding in the bracing arms

Folding out

Prerequisite The bracing arm (1) has been installed and folded in;

à Installing, p. 7 - 11.

• Remove the spring cotter from the pin (4).

• Secure the pin (5).

• Pivot the bracing arm (1) outwards.

• Remove the pin at the connecting point (6).

• Fold the support (2) so that it aligns with the connecting point (3).

• Remove the pin from connecting point (6) and insert it into connecting point (3).

• Re-insert the spring cotter on the pin (4).

• Re-insert the pin in the connecting point (5) and secure it with a spring cotter.

• Fold the bracing arm on the other side of the

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foot section in the same way.

7 - 14

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.3 Rigging work

Folding in

Prerequisite The bracing arm (1) if folded out;

à Folding out, p. 7 - 14.

• Secure the pin (1).

• Move the support (3) until the bores and the connecting point (2) align.

• Insert the pin (1) into the connecting point (2).

• Secure the pin (4).

• Pivot the bracing arm onto the foot section as shown.

• Insert the pin (4) and secure it with a spring cotter.

• Remove the spring cotter from the pin (6).

• Screw the connecting piece (5) onto the pin (6) as illustrated.

• Secure the connecting piece (5) by attaching the spring cotter to the pin (6).

• Fold the bracing arm on the other side of the

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foot section in the same way.

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7 - 15

Operation with boom extension and MWL 7.3 Rigging work

7.3.3

Shifting the deflection sheaves

From the main boom to the bracing arm

Prerequisite

G

– The MWL has been raised.

– The hand-held control unit is connected.

Risk of accidents when winding the guy rope.

The rotating deflection sheave and the running guy rope can trap parts of the body and injure you. You must therefore keep at a distance from the sheave and the rope. Have a helper help you.

• Wind off the winch a little; à p. 5 - 63.

• Hold the deflection sheave (1) by the handles (2).

In the process, have a helper help you as necessary.

• Remove the pin (4) form the connecting point (3).

• Wind the winch; à p. 5 - 63.

In the process, guide the deflection sheave (1) by the handles (2) onto the connecting point (3) on the bracing arm.

• Insert the bolt (4) into the connecting point

• Shift the deflector roller on the other side in the same way.

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MWL operating instructions GMK 6400

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(3) and secure it with a spring cotter.

Operation with boom extension and MWL 7.3 Rigging work

From the bracing arm onto the main boom

G

Risk of accidents when winding the guy rope.

The rotating deflection sheave and the running guy rope can trap parts of the body and injure you. You must therefore keep at a distance from the sheave and the rope. In the process, have a helper help you as necessary.

• Wind off the winch a little; à p. 5 - 63.

• Hold the deflection sheave (1) by the handles (2).

In the process, have a helper help you as necessary.

• Remove the pin (4) form the connecting point (3).

• Unwind the winch; à p. 5 - 63.

In the process, guide the deflection sheave (1) by the handles (2) onto the connecting point (3) on the lower head sheave axle.

• Insert the bolt (4) into the connecting point (3) and secure it with a spring cotter.

• Shift the deflector roller on the other side in 2013.04.25

the same way.

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7 - 17

Operation with boom extension and MWL 7.3 Rigging work

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7 - 18

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.4 Operation with MWL set down

7.4

Operation with MWL set down This section only describes operation with the boom extension and the MWL set down. The boom system is not braced and increased lifting capacity will not be enabled.

7.4.1

Putting the boom system into the operating condition This section assumes that the MWL has been rigged as described in the p. 5 - 1. checklist Rigging the MWL for operation with MWL set down;

à

If previously operated with the boom system braced, check that the following conditions are met.

– the deflection sheaves have been disconnected at the fastening point; Connecting/detaching the deflection sheaves to/from the lower head sheave axle, p. 5 - 49.

Raising/setting down the MWL, p. 5 - 51.

– the MWL has been set down;

à

à

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7 - 19

Operation with boom extension and MWL 7.4 Operation with MWL set down

Setting the RCL

For operation with the MWL set down, you must enter the current rigging mode for operation with the boom extension without MWL on the RCL.

• Enter the current rigging mode.

For operation with MWL set down: – the display (1) must show a truck crane with boom extension and without MWL and – the display (3) must show an RCL code for operation with the main boom, e.g. 3712.

• Confirm the selected rigging mode (Press button (4) 2x).

The symbol (2) is shown in light grey when the MWL is set down and the button next to the symbol is not active.

The RCL now takes into account the Lifting capacity table corresponding to the RCL code displayed for operation with the boom extension.

When the MWL is set down, the values specified in the lifting capacity tables are reduced.

The reduced values are shown directly on the display (1).

To calculate these values for operations planning Lifting capacity tables.

à

H

The display (1) only shows the reduced values if the MWL is connected electrically. Otherwise, the values from the lifting capacity tables will be shown – however, the reduced values still apply for shut-down of the system.

à Error messages on the RCL, p. 10 - 7.

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If error messages occur;

7 - 20

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.4 Operation with MWL set down

Telescoping

G

Telescoping with the MWL set down is performed in the same way as for operation with boom extension without MWL. Risk of damage to the deflection sheaves and guy ropes.

Make sure that the deflection sheaves are disconnected at the side fastening points and have been pulled into the guides before you telescope the main boom with the MWL set down. This way you prevent damage to the deflection sheaves or the guy ropes when telescoping.

Operation with boom extension

Operation of the power units when operating with the boom extension with the MWL set down is performed in the same way as when operating with the boom extension without MWL; Lattice extension operating manual.

7.4.2

Putting the boom system into rigging mode

à

Operation of the power units with the MWL set down is performed in the same way as when operating with the boom extension without MWL; Lattice extension operating manual.

à

This section assumes the following: – the truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal, – the actual rigging mode for operation with the boom extension is entered on the RCL.

• Set down the load.

• Check on the relevant lifting capacity table whether the rigging mode to be set can only be rigged with the superstructure positioned to the rear; p. 1 - 15. Turn the superstructure to the position 0° to the rear if necessary.

à

• Completely retract the main boom

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To continue unrigging the MWL; à CHECKLIST: Unrigging after operation with the boom extension, p. 7 - 4.

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7 - 21

Operation with boom extension and MWL 7.4 Operation with MWL set down

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7 - 22

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.5 Rigging mode with unbraced boom system and raised MWL

7.5

Rigging mode with unbraced boom system and raised MWL The rigging mode with rigged boom extension, raised MWL and unbraced boom system is not for use when telescoping.

As long as the MWL is unbraced, the RCL only enables the lifting capacity of the empty hook curve.

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G

Risk of overturning in an impermissible operating mode when RCL is overridden.

Operation with the boom extension is not permitted with the MWL raised and the boom system unbraced.

Do not under any circumstances override the RCL in this mode in order to raise loads the weight of which exceeds the values of the empty hook curve.

This way you prevent the truck crane from overturning.

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7 - 23

Operation with boom extension and MWL 7.5 Rigging mode with unbraced boom system and raised MWL

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7 - 24

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.6 Driving with rigged crane and rigged boom extension with rigged MWL

7.6

Driving with rigged crane and rigged boom extension with rigged MWL This section describes how to move the truck crane with an installed counterweight, rigged boom extension and rigged MWL. In addition to this section you must also adhere to the following: – Chapter Driving with a rigged truck crane in the Operating Instructions, – Section Driving with a rigged truck crane and rigged MWL, p. 6 - 25.

G G G 7.6.1

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.

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

Risk of accidents if your view of the truck crane is partially obstructed!

While driving, always stay in visual or radio contact with a banksman who can observe the parts which you cannot see.

Driving distance

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Please also adhere to the section Driving distance, p. 6 - 26.

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7 - 25

Operation with boom extension and MWL 7.6 Driving with rigged crane and rigged boom extension with rigged MWL

7.6.2

S Putting the truck crane into the rigging mode

Rigging modes for moving and axle loads Risk of damage to the axle lines!

Move the superstructure, the main boom and the boom extension into the specified positions only. This prevents excessive strain on the axle lines.

One of the following tables shows the required rigging mode for the procedure for the currently rigged boom extension. The rigging mode is defined by: – the position of the MWL, – the angle of the boom extension, – the counterweight combination, – the position of the superstructure, – the telescope status, – the main boom angle.

• Set down the load. No load may be raised other than the hook block.

• Set down the MWL as necessary; à Setting down the MWL, p. 5 - 59.

• If necessary, set the angle of the boom extension required for driving;

à Lattice extension operating manual.

• Reeve larger hook blocks rather than those permitted.

Permitted hook blocks, e.g.

à 12 m (39 ft)-boom extension, p. 7 - 28.

• On the RCL display, enter the current counterweight combination or the counterweight combination to which you have to unrig (e.g. 75 t) (e.g. 165 347 lbs).

• On the RCL display, enter the current rigging mode of the lattice extension:

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– the length and angle of the rigged boom extension (e.g. 24 m (79 ft) and 3°), – operation with MWL when MWL is raised.

7 - 26

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.6 Driving with rigged crane and rigged boom extension with rigged MWL

• If necessary, use an auxiliary crane to unrig to the required counterweight combination;

à Operating Instructions.

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

• Switch off the slewing gear; à Operating Instructions.

• Lock the superstructure; à Operating Instructions.

• Derrick the main boom to the required angle for telescopic extension.

You can find the required main boom angle in the Lifting capacity tables, in chapter Rigging table boom extension).

• Telescope the main boom to the required telescope status and lock the telescopic sections.

• Derrick the main boom to the position required.

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7 - 27

Operation with boom extension and MWL 7.6 Driving with rigged crane and rigged boom extension with rigged MWL

The specified axle loads apply for reeved 32 t hook blocks (weight 620 kg (1 370 lbs)).

Telescopic section telescope status I/II/III/IV

Main boom angle in °

Lattice extension inclination in °

Main boom position1)

Axle load2) in t (x 1000 lbs)

88 - 0 - 0 - 0

15

3

vorne

21,5 (47,4)

21,0 (46,3)

0-0-0-0

82

3

hinten

13,0 (28,7)

27,5 (60,6)

44 - 0 - 0 - 0

15

3

vorne

17,0 (37,5)

24,5 (54,0)

0-0-0-0

82

3

hinten

15,5 (34,2)

26,0 (57,3)

88 - 44 - 0 - 0

15

3

vorne

21,0 (46,3)

26,5 (58,4)

88 - 44 - 0 - 0

15

3

vorne

22,5 (49,6)

25,5 (56,2)

0-0-0-0

82

3

hinten

19,5 (43,0)

28,0 (61,7)

Position of the MWL

Rigged counterweight in t (lbs)

12 m (39 ft)-boom extension

abgelegt 40 (88 100) aufgerichtet (90°)

abgelegt 60 (132 200)

über 60 (132 200)

aufgerichtet (90°)

Data not available yet.

front

rear

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 60 t (132 200 lbs) abrüsten.

1)

Indicated slewing angle 0°

Front:

Indicated slewing angle 180°

Front:

on each the first and second Axle line

Rear:

on each of the 3rd to 6th Axle line

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2)

Rear:

7 - 28

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.6 Driving with rigged crane and rigged boom extension with rigged MWL

The specified axle loads apply for reeved 32 t hook blocks (weight 620 kg (1 370 lbs)).

Telescopic section telescope status I/II/III/IV

Main boom angle in °

Lattice extension inclination in °

Main boom position1)

Axle load2) in t (x 1000 lbs)

44 - 0 - 0 - 0

15

3

vorne

17,5 (38,6)

24,5 (54,0)

0-0-0-0

82

3

hinten

13,0 (28,7)

28,0 (61,7)

44 - 0 - 0 - 0

15

3

vorne

19,0 (41,9)

23,5 (51,8)

0-0-0-0

82

3

hinten

15,0 (33,1)

26,0 (57,3)

88 - 44 - 0 - 0

15

3

vorne

23,0 (50,7)

25,5 (56,2)

88 - 0 - 0 - 0

15

3

vorne

20,0 (44,1)

27,5 (60,6)

0-0-0-0

82

3

hinten

19,5 (43,0)

28,0 (61,7)

Position of the MWL

Rigged counterweight in t (lbs)

18 m (59 ft)-boom extension

abgelegt 40 (88 100) aufgerichtet (90°)

abgelegt 60 (132 200)

über 60 (132 200)

aufgerichtet (90°)

Data not available yet.

front

rear

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 60 t (132 200 lbs) abrüsten.

1)

2)

Rear:

Indicated slewing angle 0°

Front:

Indicated slewing angle 180°

Front:

on each the first and second Axle line

Rear:

on each of the 3rd to 6th Axle line

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7 - 29

Operation with boom extension and MWL 7.6 Driving with rigged crane and rigged boom extension with rigged MWL

The specified axle loads apply for reeved 32 t hook blocks (weight 620 kg (1 370 lbs)).

Telescopic section telescope status I/II/III/IV

Main boom angle in °

Lattice extension inclination in °

Main boom position1)

Axle load2) in t (x 1000 lbs)

44 - 0 - 0 - 0

15

3

vorne

19,0 (41,9)

23,5 (51,8)

0-0-0-0

82

3

hinten

13,0 (28,7)

28,0 (61,7)

44 - 0 - 0not - 0 available 15 3yet.

Data

vorne

20,5 (45,2)

22,5 (49,6)

0-0-0-0

82

3

hinten

15,5 (33,1)

26,5 (58,4)

abgelegt

88 - 0 - 0 - 0

15

3

vorne

20,5 (45,2)

27,5 (60,6)

aufgerichtet (90°)

88 - 0 - 0 - 0

15

3

vorne

22,0 (48,5)

26,0 (57,3)

Position of the MWL

Rigged counterweight in t (lbs)

24 m (79 ft)-boom extension

abgelegt 40 (88 100) aufgerichtet (90°)

60 (132 200) über 60 (132 200)

front

rear

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 60 t (132 200 lbs)abrüsten.

1)

Indicated slewing angle 0°

Front:

Indicated slewing angle 180°

Front:

on each the first and second Axle line

Rear:

on each of the 3rd to 6th Axle line

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2)

Rear:

7 - 30

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MWL operating instructions GMK 6400

Operation with boom extension and MWL 7.6 Driving with rigged crane and rigged boom extension with rigged MWL

7.6.3

Driving

Before driving

• Check the tyre pressure and the wind speed;

à Operating Instructions.

• Check whether

à

– the slewing gear is switched off; Operating Instructions.

– the superstructure is locked; Operating Instructions.

à

• Place the truck crane on the wheels; à 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.

Driving from the driver's cab

• Engage the lowest starting gear; à 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 Operating Instructions.

If required, you can – switch on the longitudinal differential locks, – Switch on the transverse differential locks While driving

• Drive only at the lowest possible speed, maximum 1.5 km/h (1 mph).

• The turning radius should be as large as possible when driving around corners!

• Steer the truck crane only when it is rolling and avoid sudden steering movements.

S G

Risk of damage to the steering linkage!

The steering linkage can be damaged if the steering is operated while the vehicle is stationary.

Danger of overturning when switching on the suspension!

The suspension must be deactivated (locked) as long as the rigged truck crane is on wheels.

When switching on the suspension, the suspension cylinders would suddenly be pressed together and damaged, and the truck crane could overturn.

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7 - 31

Operation with boom extension and MWL 7.6 Driving with rigged crane and rigged boom extension with rigged MWL

After driving

• Switch the separate steering off after driving; à Operating Instructions.

• Apply the parking brake; à Operating Instructions.

Set the truck crane down on the outrigger span required for the scheduled Operating Instructions. operation;

à

If necessary, rig the counterweight sections

If you have rigged the counterweight sections before moving, you have to now rig these sections again.

• On the RCL display, enter the counterweight combination to which you have to unrig (e.g. 95 t) (e.g. 209 439 lbs).

• Rig the relevant counterweight parts with an auxiliary crane. Procedure

à Operating Instructions.

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for rigging;

7 - 32

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MWL operating instructions GMK 6400

8 8

Operation with luffing jib and MWL

8.1

Further rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

3

8.1.1 8.1.2

CHECKLIST: Rigging for operation with luffing jib . . . . . . . . . . . . . . . . . . . . . . . 8 CHECKLIST: Unrigging after operation with the luffing jib . . . . . . . . . . . . . . . . . 8 -

3 4

8.2

Operation with braced boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

5

CHECKLIST: Putting the boom system into the operating condition . . . . . . . . 8 - 5 CHECKLIST: Putting the boom system into rigging mode . . . . . . . . . . . . . . . . . 8 - 9 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13 Derricking main boom with rigged luffing jib and rigged MWL . . . . . . . . . . . . . 8 - 15 Telescoping the main boom with rigged luffing jib and rigged MWL . . . . . . . . 8 - 16 Bracing the boom system with rigged luffing jib. . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18

8.3

Operation with MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19

8.3.1 8.3.2

Putting the boom system into the operating condition. . . . . . . . . . . . . . . . . . . . 8 - 19 Putting the boom system into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21

8.4

Rigging mode with unbraced boom system and raised MWL . . . . . . . . . . . . . . . 8 - 23

8.5

Driving with rigged crane and rigged luffing jib with rigged MWL . . . . . . . . . . . 8 - 25

8.5.1 8.5.2 8.5.3

Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25 Rigging modes for moving and axle loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 26 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35

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8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6

MWL operating instructions GMK 6400

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MWL operating instructions GMK 6400

Operation with luffing jib and MWL

8

Operation with luffing jib and MWL

G H

Risk of accidents if the safety instructions are ignored For operation of the luffing jib with MWL all the warnings in the lattice extension operating manual apply.

This chapter merely supplements the lattice extension operating manual with additional information required when operating the luffing jib together with the MWL.

This chapter assumes that you are already familiar with the unrigging procedure for the luffing jib without MWL. Therefore, procedures such as raising the luffing jib are only briefly described in checklists. If you require more detailed information on simple operation of the luffing jib, refer to the lattice extension operating manual included in the scope of delivery.

This chapter provides you with information on the further procedure for operation using the luffing jib with MWL after rigging of the MWL. Section Further rigging work – The section contains information on the further rigging procedure and on preparation for rigging for operation with the luffing jib and MWL. Section Operation with braced boom system – The section contains all the information required for setting the RCL, telescoping with the MWL rigged, folding in and out and bracing the boom system with luffing jib.

Section Operation with MWL set down – The section contains all the information required on operation of the luffing jib when the MWL is rigged but neither raised nor braced.

Section Driving with rigged crane and rigged luffing jib with rigged MWL

2013.04.25

– The section contains the required information on boom positions, special rigging codes and the axle loads generated when driving the truck crane with rigged MWL.

MWL operating instructions GMK 6400

3 112 978 en

8-1

Operation with luffing jib and MWL

2013.04.25

Blank page

8-2

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MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.1 Further rigging work

8.1

Further rigging work

8.1.1

CHECKLIST: Rigging for operation with luffing jib

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. The MWL has been rigged as described in the chapter Rigging and unrigCHECKLIST: Rigging the MWL, p. 5 - 1. ging the MWL;

à

2. The auxiliary hoist has been rigged;

à Operating Instructions.

3. Check on the relevant lifting capacity table whether the rigging mode to be set can only be rigged with the superstructure positioned to the rear; p. 1 - 15. Turn the superstructure to the position 0° to the rear if necessary.

à

4. If the MWL has been set down, rig the luffing jib as described in the lattice extension operating manual.

à

5. Fold down the bracing arm; p. 7 - 14.

Install the bracing arm beforehand as necessary;

à p. 7 - 11.

6. Shift the deflection sheaves from the lower head sheave axle onto the p. 7 - 16. bracing arm;

à

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7. Bring the boom system into the operating condition required: – For operation with braced boom system; – For operation with MWL set down;

MWL operating instructions GMK 6400

3 112 978 en

à p. 8 - 5,

à p. 8 - 19.

8-3

Operation with luffing jib and MWL 8.1 Further rigging work

8.1.2

CHECKLIST: Unrigging after operation with the luffing jib

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. Bring the boom system into the rigging mode required: – After operation with braced boom system; – After operation with MWL set down;

à p. 8 - 9,

à p. 8 - 21.

2. The current rigging mode for operation with the luffing jib is entered on the RCL; Setting the RCL, p. 8 - 13.

à

3. Shift the deflection sheaves from the bracing arms onto the lower head p. 7 - 17. sheave axle;

à

à

4. Fold in the bracing arms; p. 7 - 15.

If necessary, remove the bracing arm;

à p. 7 - 12.

5. Unrig the luffing jib as described in the Lattice extension operating manual.

à CHECKLIST: Unrigging the MWL, 2013.04.25

6. To continue unrigging the MWL; p. 5 - 7.

8-4

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MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.2 Operation with braced boom system

8.2

Operation with braced boom system This section describes operation with luffing jib and braced boom system, which enables increased lifting capacity.

For operation with the MWL rigged but not raised; set down, p. 8 - 19.

8.2.1

à Operation with MWL

CHECKLIST: Putting the boom system into the operating condition

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. Enter the current rigging mode for operation with the luffing jib and MWL for a main boom angle of 81°; Setting the RCL, p. 8 - 13.

à

2. Open the Luffing jib submenu

0; à Lattice extension operating manual

3. Raise the luffing control arm so that the symbol (1) is shown in yellow.

The auxiliary hoist is then shut off.

4. From the Luffing jib submenu, first switch to the Operation-MWL submenu . From there, switch to the submenu Rigging-MWL .

U

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1

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8-5

Operation with luffing jib and MWL 8.2 Operation with braced boom system

5. Raise the MWL so that the symbol (1) is shown in green; p. 5 - 58.

à Raise MWL,

6. From the Rigging-MWL submenu, first switch to the Operation-MWL . From there, switch to the Luffing jib submenu . submenu

1

0

7. Raise main boom so that the upper section of the indicator lamp (1) changes from red to grey (RCL display, luffing jib angle approx. 10°).

The movement Lift auxiliary hoist is now enabled.

8. Raise the luffing jib to the height required for reeving the main hoist rope.

9. Reeve the main hoist rope on the hook block and place the lifting limit switch weight around the hoist rope.

10. If necessary, remove the block from the lifting limit switch; Operating Instructions GMK 6400.

2013.04.25

à

8-6

3 112 978 en

MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.2 Operation with braced boom system

11. Enter the current reeving on the RCL;

à operating instructions.

à Derricking main boom with rigged luffing jib

12. Raise main boom to 81°; and rigged MWL, p. 8 - 15.

13. Derrick luffing jib into telescoping range (1); ing manual.

à Lattice extension operat-

14. Telescope the main boom out to a permissible position as per lifting capacity table; Telescoping the main boom with rigged luffing jib and rigged MWL, p. 8 - 16.

à

15. From the Luffing jib submenu, switch to the Operation-MWL submenu .

1

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3 112 978 en

8-7

Operation with luffing jib and MWL 8.2 Operation with braced boom system

16. Fold out both gantry masts;

à Folding the gantry masts out/in, p. 6 - 9.

17. Derrick the luffing jib to the bracing angle required and brace the boom Bracing the boom system with rigged luffing jib, p. 8 - 18. system;

à

If operation at a main boom angle of 60° or 70° is required: 18. Enter the rigging mode with luffing jib and MWL for the required main Setting the RCL, p. 8 - 13. boom angle (60° or 70°) on the RCL;

à

à lattice extension

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19. Lower the main boom into the required position; operating manual.

8-8

3 112 978 en

MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.2 Operation with braced boom system

8.2.2

CHECKLIST: Putting the boom system into rigging mode

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. The truck crane is supported with the outrigger span required for the previous operation, and aligned horizontally.

2. The current rigging mode for operation with the luffing jib and MWL has been entered on the RCL; Setting the RCL, p. 8 - 13.

à

3. Set down the load; other than the hook block, no load may be raised.

4. Check on the relevant lifting capacity table whether the rigging mode to be set can only be rigged with the superstructure positioned to the rear; p. 1 - 15. Turn the superstructure to the position 0° to the rear if necessary.

à

5. From the Luffing jib submenu, switch to the Operation-MWL submenu .

1

à Derricking main boom with rigged luffing jib

6. Raise main boom to 80°; and rigged MWL, p. 8 - 15.

7. To relieve the boom system, unlock the winches; p. 6 - 15.

à Unlocking winches,

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8-9

Operation with luffing jib and MWL 8.2 Operation with braced boom system

8. Fold in both gantry masts;

à Folding the gantry masts out/in, p. 6 - 9.

9. Derrick the luffing jib into telescoping range (1); ating manual.

à lattice extension oper-

à

Telescoping the main boom with 10. Retract the main boom completely; rigged luffing jib and rigged MWL, p. 8 - 16.

11. Switch from the submenu Operation-MWL to the Luffing jib sub. menu

0

12. Lower the main boom until the head section of the luffing jib is just above the ground, while at the same time lowering the luffing jib so that the steepest position is not reached.

2013.04.25

S

Risk of damage to the hoist rope!

Make sure that the hoist rope is not damaged. During the following procedures, set down the hook block as soon as the boom system is in a suitable position for doing so, and unreeve the main hoist rope.

8 - 10

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MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.2 Operation with braced boom system

S

Risk of damage to the fall-back guard strut During the following procedure, make sure that the head section does not touch the ground before the luffing control arm has reached the steepest position. When the luffing control arm is inclined forwards, the fall-back guard strut may come into contact with the foot section and may become damaged (the luffing jib has been set down flat on the ground).

13. Without touching the ground, move the head section towards the front (combination of lowering the main boom and raising the luffing jib) until the luffing jib is positioned just before the too steep shut-down range (1) in the current position display (RCL display, luffing jib angle approx. 10°).

14. Lower the main boom to set the luffing jib down on the ground using the rollers on the head. Then lower the main boom so that the upper section of the lamp (1) is shown in red. Lowering is then shut off.

15. Lower the luffing control arm so that the symbol (1) is shown in grey.

G

Risk of accidents if the main boom is lowered too far In the next step, only lower the main boom far enough to allow the locking pin positions for the hinge lock to align. This position may be exceeded when lowering the boom to the horizontal position, especially with long luffing jibs. The inclinable part of the foot section is pressed against the fixed part; this causes tension. This tension is released when the pins are driven out. This in turn causes the luffing jib to slip unexpectedly and can injure you or others.

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8 - 11

Operation with luffing jib and MWL 8.2 Operation with braced boom system

16. Lower the main boom so that the locking points for the hinge lock in the foot section are aligned.

17. First switch from the Luffing jib submenu to the Operation-MWL submenu . From there, switch to the submenu Rigging-MWL .

1

U

18. Disconnect the guy rope pulleys from the fastening points on the bracing arms and pull them into the guides; p. 5 - 50.

à

19. Set down the MWL;

à Setting down the MWL, p. 5 - 59.

20. Lock both winches;

à Locking winches, p. 6 - 14.

22. To continue unrigging the MWL; tion with the luffing jib, p. 8 - 4.

8 - 12

3 112 978 en

à CHECKLIST: Unrigging after opera-

MWL operating instructions GMK 6400

2013.04.25

21. Set the luffing control arm down on the the rigging supports (lower auxiliary hoist).

Operation with luffing jib and MWL 8.2 Operation with braced boom system

8.2.3

Setting the RCL The current rigging mode for operation with the luffing jib is entered on the RCL. The MWL is then entered into this rigging mode.

The Enter rigging mode submenu shows the rigging mode entered, e.g.: – Counterweight combination 95 t, – Luffing jib 37 m (121 ft) without angle, 0°, – Main boom angle 80°, – Outrigger span of 8.70 x 8.50 m (28.5 x 27.9 ft), – Slewing range ±180°.

The display (3) shows the corresponding RCL code, e.g. 5712.

The display (1) shows a truck crane with luffing jib.

• Press the button (2) once.

The button is only active when the MWL is in the raised to 90° position:

H

If it is not permissible to operate the MWL with the rigging mode shown, there is no change on the display.

If operation with the MWL is permissible with the rigging mode shown: – the symbol (2) is shown in green, – the display (1) shows a truck crane with luffing jib and MWL, – the display (3) indicates the corresponding RCL code for operation with MWL, e.g. 7712.

• Confirm the selected rigging mode (Press button (4) 2x).

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8 - 13

Operation with luffing jib and MWL 8.2 Operation with braced boom system

The submenu RCL monitoring now shows the selected rigging mode with MWL. The display (1) shows the load of the rigging programme for the current rigging mode as per the lifting capacity table, e.g. 5.0 t (11 000 lbs).

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The RCL only enables the increased load bearing capacities for operation with MWL when the MWL is braced.

8 - 14

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MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.2 Operation with braced boom system

8.2.4

Derricking main boom with rigged luffing jib and rigged MWL The procedure for derricking the main boom with rigged luffing jib and MWL is the same as with a rigged luffing jib without MWL; Lattice extension operating manual.

à

Nevertheless, the requirements for derricking with rigged MWL have to be met before enabling the derricking procedure.

• Check that the following conditions are met: In the Operation-MWL submenu The display (1) shows: – either symbol (2) is in green, – or symbol (3) is in green.

In the Luffing jib submenu: – The indicator lamp in the symbol (3) is shown in green.

– The display (1) indicates the rigging range in green.

– The display (4) is shown in green.

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– Both halves are shown on the display (2) in grey.

MWL operating instructions GMK 6400

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8 - 15

Operation with luffing jib and MWL 8.2 Operation with braced boom system

8.2.5

Telescoping the main boom with rigged luffing jib and rigged MWL The procedure for telescoping with rigged luffing jib and MWL is the same Lattice extension operating manas with a rigged luffing jib without MWL; ual.

à

Nevertheless, the requirements for telescoping with rigged MWL have to be met before the telescoping procedure is enabled. Check that the following conditions are met: – There is no load raised other than the hook block.

– The main boom is positioned at 80°.

On the RCL display – Enter rigging mode submenu: – A main boom angle of 80° has been selected on the display (1).

– The display (2) shows an RCL code for operation with luffing jib and MWL for a main boom angle of 80° (e.g. 7712).

In the Operation-MWL submenu – Both winches are unlocked. The symbols (1) for the end position Unlocked are shown in red.

– Both gantry masts are folded in. The symbols (2) for the end position are shown in green.

In the Luffing jib submenu: – The display (3) is shown in grey.

– The luffing jib is in telescoping range (1).

– The indicator lamp in the symbol (2) is shown in green.

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– The display (4) is shown in green.

8 - 16

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MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.2 Operation with braced boom system

H

The telescoping procedure is enabled once all requirements have been met.

It is a good idea to use the teleautomation after opening the Luffing jib submenu since the shut-down ranges are also displayed in this menu. You can also start the teleautomation from the Operation-MWL submenu or in the Telescoping submenu.

Further information on telescoping and the automatic following movement Lattice extension operating manual. of the luffing jib;

à

If long luffing jibs are rigged, it is possible that the main boom will not telescope any further although the luffing jib is positioned in the telescoping range (1).

In this case you have to raise the luffing jib to a steeper angle.

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H

When teleautomation is switched on, the luffing jib is raised automatically to the required angle. The telescoping function is not interrupted.

MWL operating instructions GMK 6400

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8 - 17

Operation with luffing jib and MWL 8.2 Operation with braced boom system

8.2.6

Bracing the boom system with rigged luffing jib Before the bracing procedure can be enabled, all the requirements for bracing with rigged luffing jib without MWL must be met ( p. 6 - 12).

à

In addition, the following requirements must be met: – The main boom must be raised to an angle of 80°.

– A main boom angle of 80° has been selected on the display (1) and the display (2) indicates an RCL code for operation with luffing jib and MWL with a main boom angle of 80 (e.g. 7712).

• Derrick the luffing jib to 7°.

The entry =7° must be shown in green in the symbol (3).

Once all the requirements have been met: – The symbol on the display (1) is shown in green.

– The symbol (2) is shown in black and the button is active.

à Bracing,

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To brace the boom system; p. 6 - 12.

8 - 18

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MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.3 Operation with MWL set down

8.3

Operation with MWL set down This section only describes operation with the luffing jib and the MWL set down. The boom system is not braced and increased lifting capacity will not be enabled.

For operation with braced boom system;

8.3.1

à p. 8 - 5,

Putting the boom system into the operating condition This section assumes that the MWL has been rigged as described in the checklist Rigging the MWL for operation with MWL set down.

If previously operated with the boom system braced, check that the following conditions are met.

– the deflection sheaves have been disconnected at the fastening point; Connecting/detaching the deflection sheaves to/from the lower head sheave axle, p. 5 - 49.

Raising/setting down the MWL, p. 5 - 51.

– the MWL has been set down;

à

à

2013.04.25

s

MWL operating instructions GMK 6400

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8 - 19

Operation with luffing jib and MWL 8.3 Operation with MWL set down

Setting the RCL

For operation with the MWL set down, you must enter the current rigging mode for operation with the luffing jib without MWL on the RCL.

• Enter the current rigging mode.

For operation with MWL set down: – the display (1) must show a truck crane with luffing jib and without MWL and – the display (3) must show an RCL code for operation with the main boom, e.g. 5712.

• Confirm the selected rigging mode (Press button (4) 2x).

The symbol (2) is shown in grey when the MWL is set down and the button next to the symbol is not active.

The RCL now takes into account the Lifting capacity table corresponding to the RCL code displayed for operation with the luffing jib.

When the MWL is set down, the values specified in the Lifting capacity tables are reduced.

The reduced values are shown directly on the display (1).

To calculate these values for operations planning Lifting capacity tables.

à

H

The display (1) only shows the reduced values if the MWL is connected electrically. Otherwise, the values from the lifting capacity tables will be shown – however, the reduced values still apply for shut-down of the system.

à Error messages on the RCL, p. 10 - 7.

2013.04.25

If error messages occur;

8 - 20

3 112 978 en

MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.3 Operation with MWL set down

Telescoping

G

Telescoping with the MWL set down is done in the same way as for operation with luffing jib without MWL; Lattice extension operating manual.

à

Risk of damage to the deflection sheaves and guy ropes.

Make sure that the deflection sheaves are disconnected at the side fastening points and have been pulled into the guides before you telescope the main boom with the MWL set down. This way you prevent damage to the deflection sheaves or the guy ropes when telescoping.

Operating with the luffing jib

Operation of the power units when operating with the luffing jib with the MWL set down is performed in the same way as when operating with the Lattice extension operating manual. luffing jib without MWL;

8.3.2

Putting the boom system into rigging mode

à

Operation of the power units with the MWL set down is performed in the same way as when operating with the luffing jib without MWL; Lattice extension operating manual.

à

This section assumes the following: – the truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal, – the actual rigging mode for operation with the luffing jib has been entered on the RCL.

• Set down the load.

• Check on the relevant lifting capacity table whether the rigging mode to be set can only be rigged with the superstructure positioned to the rear; p. 1 - 15. Turn the superstructure to the position 0° to the rear if necessary.

à

• Fully retract the main boom.

• Slew the superstructure into the position for unrigging the luffing jib and derrick the main boom into the horizontal position.

à CHECKLIST: Unrigging after operation

2013.04.25

To continue unrigging the MWL; with the luffing jib, p. 8 - 4.

MWL operating instructions GMK 6400

3 112 978 en

8 - 21

Operation with luffing jib and MWL 8.3 Operation with MWL set down

2013.04.25

Blank page

8 - 22

3 112 978 en

MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.4 Rigging mode with unbraced boom system and raised MWL

8.4

Rigging mode with unbraced boom system and raised MWL The rigging mode with rigged luffing jib, raised MWL and unbraced boom system is not for use when telescoping.

As long as the MWL is not braced, the RCL only enables the lifting capacity of the empty hook curve.

2013.04.25

G

Risk of overturning in an impermissible operating mode when RCL is overridden.

Operation with the luffing jib is not permitted with the MWL raised and the boom system unbraced.

Do not under any circumstances override the RCL in this mode in order to raise loads the weight of which exceeds the values of the empty hook curve.

This way you prevent the truck crane from overturning.

MWL operating instructions GMK 6400

3 112 978 en

8 - 23

Operation with luffing jib and MWL 8.4 Rigging mode with unbraced boom system and raised MWL

2013.04.25

Blank page

8 - 24

3 112 978 en

MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

8.5

Driving with rigged crane and rigged luffing jib with rigged MWL This section describes how to move the truck crane with an installed counterweight, rigged luffing jib and rigged MWL. In addition to this section you must also adhere to the following: – Chapter Driving with a rigged truck crane in the Operating Instructions, – Section Driving with a rigged truck crane and rigged MWL, p. 6 - 25.

G G G 8.5.1

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.

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

Risk of accidents if your view of the truck crane is partially obstructed!

While driving, always stay in visual or radio contact with a banksman who can observe the parts which you cannot see.

Driving distance

2013.04.25

Please also adhere to the section Driving distance, p. 6 - 26.

MWL operating instructions GMK 6400

3 112 978 en

8 - 25

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

8.5.2

S

Rigging modes for moving and axle loads Risk of damage to the axle lines!

Move the superstructure, the main boom and the luffing jib into the specified positions only. This prevents excessive strain on the axle lines.

• Set the current rigging mode on the RCL. • Set down the load. No load may be raised other than the hook block.

• Raise the main boom to 80°; à p. 8 - 15.

• Derrick the luffing jib into the telescoping range; à p. 8 - 16.

• Completely retract the main boom to the telescope status 0/0/0/0;

à p. 8 - 16.

One of the following tables shows the required rigging mode for the procedure for the currently rigged luffing jib. The rigging mode is defined by: – the position of the superstructure, – the counterweight combination, – the telescope status, – the main boom angle, – the luffing jib angle and – the position of the MWL.

• Check which rigging mode components have to be modified for driving and proceed as follows:

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

• Switch off the slewing gear; à Operating Instructions.

2013.04.25

• Lock the superstructure; à Operating Instructions.

8 - 26

3 112 978 en

MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

If counterweight sections need to be unrigged: The following conditions must be met: – the superstructure is positioned in the required position (0° or 180°), – the main boom is raised to 80°, – the main boom is fully retracted (0/0/0/0).

G

Risk of overturning in other rigging modes Before you unrig the counterweight sections: – check whether the above requirements have been met, – enter the RCL rigging code for telescoping or derricking, – unrig the counterweight sections.

After unrigging, the truck crane is in a rigging mode which can only be monitored by this rigging code.

This rigging code can only be accepted if the above requirements have been met.

• Set the counterweight combination to which you have to unrig on the RCL (e.g. 55 t (121 250 lbs)).

• Set the current rigging mode of the lattice extension on the RCL: – the length and the angle (e.g. 31 m (102 ft) and 0°), – operation with MWL when the MWL is raised, – a main boom angle of 80°; Setting the RCL, p. 8 - 13.

à

• Set the telescoping rigging code for the currently rigged lattice extension on the RCL (e.g. 7511 with rigged 31 m luffing jib and counterweight combination 55 t (121 250 lbs)).

• Unrig the necessary counterweight parts with an auxiliary crane. Procedure for unrigging;

à operating instructions.

2013.04.25

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MWL operating instructions GMK 6400

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8 - 27

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

When it is necessary to extend main boom telescoping:

• Switch on the Telescopic extension operating mode.

• Set the telescoping rigging code for the currently rigged lattice extension on the RCL display (e.g. 7511 for rigged 31 m (102 ft) luffing jib and counterweight combination 55 t (121 250 lbs)).

G

Risk of accidents due to incorrectly set or bypassed RCL. For the rigging modes that are given in the following tables, telescoping is only monitored if the respective RCL rigging code is entered for telescoping.

Do not enter any other RCL code and do not bypass the RCL. This way you prevent the truck crane from overturning.

• Telescope the main boom as required as per the following tables (e.g. 44/44/44/44). Requirements for telescoping;

à p. 8 - 16.

If main booms or luffing jibs have to be derricked:

• Switch on operation with the luffing jib.

G 8 - 28

Risk of accidents due to incorrectly set or bypassed RCL. For the rigging modes that are given in the following tables, derricking the main boom is only monitored if the respective RCL rigging code is entered for Derricking.

Do not enter any other RCL code and do not bypass the RCL. This way you prevent the truck crane from overturning.

3 112 978 en

MWL operating instructions GMK 6400

2013.04.25

Set the derricking rigging code for the currently rigged lattice extension on the RCL display (e.g. 7521 for rigged 31 m (102 ft) luffing jib and counterweight combination 55 t (121 250 lbs)).

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

• Derrick the main boom to the required angle as per the following tables (e.g. 60°).

• Derrick the luffing jib to the required angle as per the following tables (e.g. 45°).

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MWL operating instructions GMK 6400

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8 - 29

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

Information about the tables

The specified axle loads apply for reeved 32 t hook blocks (weight 620 kg (1 370 lbs)).

The following applies to the foot notes in the tables: 1)

2)

25 m (82 ft) luffing jib

Rear:

Indicated slewing angle 0°

Front:

Indicated slewing angle 180°

Front:

on each the first and second Axle line

Rear:

on each of the 3rd to 6th Axle line

Adhere to the information on the foot notes in the section Information about the tables; p. 8 - 30.

à

HauptauslegerStellung1)

Wippen

Neigung Spitzenausleger in °

aufgerichtet (90°)

Teleskopieren

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

88 / 88 / 0 / 0

60

45

vorn

17,5 (38,6)

27,5 (60,6)

60

45

vorn

16,5 (36,4)

28,0 (61,7)

Data not available yet.

8320

Achslast 2) in t (x 1000 lbs)

8520

88 / 88 / 0 / 0

vorne

hinten

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 40 t (88 100 lbs) abrüsten.

2013.04.25

über 40 (88,1)

abgelegt

Rüstcode für Neigung Hauptausleger in °

40 (88,1)

Stellung des MWL

Gegengewicht in t (lbs x 1000)

Luffing jib with angle 0°

8 - 30

3 112 978 en

MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

Adhere to the information on the foot notes in the section Information about p. 8 - 30. the tables;

31 m (102 ft) luffing jib

à

Luffing jib with angle 0°

über 40 (88,1)

Neigung Spitzenausleger in °

HauptauslegerStellung1)

Wippen

60

45

vorn

17,0 (37,5)

28,0 (61,7)

60

45

vorn

19,0 (41,9)

26,5 (58,4)

Data not available yet.

8321

aufgerichtet (90°)

Achslast 2) in t (x 1000 lbs)

Neigung Hauptausleger in °

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

88 / 44 / 0 / 0

Teleskopieren

Stellung des MWL abgelegt

Gegengewicht in t (lbs x 1000) 40 (88,1)

Rüstcode für

8521

88 / 88 / 0 / 0

vorne

hinten

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 40 t (88 100 lbs) abrüsten.

Adhere to the information on the foot notes in the section Information about p. 8 - 30. the tables;

37 m (121 ft) luffing jib

à

2013.04.25

über 40 (88,1)

HauptauslegerStellung1)

60

45

vorn

19,5 (43,0)

26,0 (57,3)

60

45

vorn

19,0 (41,9)

27,0 (59,5)

Data not available yet.

8322

Achslast 2) in t (x 1000 lbs)

Neigung Spitzenausleger in °

aufgerichtet (90°)

Wippen

88 / 44 / 0 / 0

Teleskopieren

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

abgelegt

Rüstcode für Neigung Hauptausleger in °

40 (88,1)

Stellung des MWL

Gegengewicht in t (lbs x 1000)

Luffing jib with angle 0°

8522

88 / 44 / 0 / 0

vorne

hinten

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 40 t (88 100 lbs) abrüsten.

s MWL operating instructions GMK 6400

3 112 978 en

8 - 31

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

Adhere to the information on the foot notes in the section Information about p. 8 - 30. the tables;

43 m (141 ft) luffing jib

à

Luffing jib with angle 0°

über 40 (88,1)

HauptauslegerStellung1)

Wippen

Neigung Spitzenausleger in °

aufgerichtet (90°)

60

45

vorn

19,5 (43,0)

26,5 (58,4)

60

45

vorn

18,5 (40,8)

27,5 (60,6)

Data not available yet.

8323

Achslast 2) in t (x 1000 lbs)

Neigung Hauptausleger in °

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

88 / 0 / 0 / 0

Teleskopieren

Stellung des MWL abgelegt

Gegengewicht in t (lbs x 1000) 40 (88,1)

Rüstcode für

8523

88 / 0 / 0 / 0

vorne

hinten

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 40 t (88 100 lbs) abrüsten.

Adhere to the information on the foot notes in the section Information about the tables; p. 8 - 30.

49 m (161 ft) luffing jib

à

8 - 32

HauptauslegerStellung1)

vorne

hinten

Wippen

Neigung Spitzenausleger in °

aufgerichtet (90°)

Teleskopieren

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

88 / 0 / 0 / 0

60

45

vorn

18,0 (39,7)

28,0 (61,7)

60

45

vorn

21,5 (47,4)

25,5 (56,2)

Data not available yet.

8324

Achslast 2) in t (x 1000 lbs)

8524

88 / 0 / 0 / 0

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 40 t (88 100 lbs) abrüsten.

2013.04.25

über 40 (88,1)

abgelegt

Rüstcode für Neigung Hauptausleger in °

40 (88,1)

Stellung des MWL

Gegengewicht in t (lbs x 1000)

Luffing jib with angle 0°

3 112 978 en

MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

Adhere to the information on the foot notes in the section Information about p. 8 - 30. the tables;

55 m (180 ft) luffing jib

à

Luffing jib with angle 0°

über 40 (88,1)

Neigung Spitzenausleger in °

HauptauslegerStellung1)

Wippen

60

45

vorn

21,5 (47,4)

25,5, (56,2)

60

45

vorn

20,5 (45,2)

26,5 (58,4)

Data not available yet.

8325

aufgerichtet (90°)

Achslast 2) in t (x 1000 lbs)

Neigung Hauptausleger in °

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

44 / 0 / 0 / 0

Teleskopieren

Stellung des MWL abgelegt

Gegengewicht in t (lbs x 1000) 40 (88,1)

Rüstcode für

8525

44 / 0 / 0 / 0

vorne

hinten

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 40 t (88 100 lbs) abrüsten.

Adhere to the information on the foot notes in the section Information about the tables; p. 8 - 30.

61 m (200 ft) luffing jib

à

2013.04.25

über 40 (88,1)

HauptauslegerStellung1)

60

45

vorn

20,0 (44,1)

27,0 (59,5)

60

45

vorn

19,0 (41,9)

27,5 (60,6)

Data not available yet.

8326

Achslast 2) in t (x 1000 lbs)

Neigung Spitzenausleger in °

aufgerichtet (90°)

Wippen

0/0/0/0

Teleskopieren

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

abgelegt

Rüstcode für Neigung Hauptausleger in °

40 (88,1)

Stellung des MWL

Gegengewicht in t (lbs x 1000)

Luffing jib with angle 0°

8526

0/0/0/0

vorne

hinten

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 40 t (88 100 lbs) abrüsten.

s MWL operating instructions GMK 6400

3 112 978 en

8 - 33

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

Adhere to the information on the foot notes in the section Information about p. 8 - 30. the tables;

67 m (220 ft) luffing jib

à

Luffing jib with angle 0°

über 40 (88,1)

HauptauslegerStellung1)

Wippen

Neigung Spitzenausleger in °

aufgerichtet (90°)

60

45

vorn

22,5 (49,6)

25,0 (55,1)

60

45

vorn

21,5 (47,4)

26,0 (57,3)

Data not available yet.

8327

Achslast 2) in t (x 1000 lbs)

Neigung Hauptausleger in °

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

0/0/0/0

Teleskopieren

Stellung des MWL abgelegt

Gegengewicht in t (lbs x 1000) 40 (88,1)

Rüstcode für

8527

0/0/0/0

vorne

hinten

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 40 t (88 100 lbs) abrüsten.

Adhere to the information on the foot notes in the section Information about p. 8 - 30. the tables;

73 m (240 ft) luffing jib

à

8 - 34

Neigung Spitzenausleger in °

HauptauslegerStellung1)

0/0/0/0

60

30

vorn

23,0 (50,7)

25,0 (55,1)

60

30

vorn

22,0 (48,5)

25,5 (56,2)

Data not available yet.

8328

Achslast 2) in t (x 1000 lbs)

Neigung Hauptausleger in °

aufgerichtet (90°)

Wippen

0/0/0/0

Teleskopieren

abgelegt

Rüstcode für

8528

vorne

hinten

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 40 t (88 100 lbs) abrüsten.

2013.04.25

über 40 (88,1)

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

40 (88,1)

Stellung des MWL

Gegengewicht in t (lbs x 1000)

Luffing jib with angle 0°

3 112 978 en

MWL operating instructions GMK 6400

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

8.5.3

Driving

Before driving

• Check the tyre pressure and the wind speed;

à Operating Instructions.

• Check whether

à

– the slewing gear is switched off; Operating Instructions.

– the superstructure is locked; Operating Instructions.

à

• Place the truck crane on the wheels; à 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.

Driving from the driver's cab

• Engage the lowest starting gear; à 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 Operating Instructions.

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

While driving

• Drive only at the lowest possible speed, maximum 1.5 km/h (1 mph).

• The turning radius should be as large as possible when driving around corners!

• Steer the truck crane only when it is rolling and avoid sudden steering movements.

Danger of overturning when switching on the suspension!

The suspension must be deactivated (locked) as long as the rigged truck crane is on wheels.

When switching on the suspension, the suspension cylinders would suddenly be pressed together and damaged, and the truck crane could overturn.

2013.04.25

S G

Risk of damage to the steering linkage!

The steering linkage can be damaged if the steering is operated while the vehicle is stationary.

s MWL operating instructions GMK 6400

3 112 978 en

8 - 35

Operation with luffing jib and MWL 8.5 Driving with rigged crane and rigged luffing jib with rigged MWL

After driving

• Switch the separate steering off after driving; à Operating Instructions.

• Apply the parking brake; à Operating Instructions.

Set the truck crane down on the outrigger span required for the scheduled Operating Instructions. operation;

à

If necessary, rig the counterweight sections

If you have rigged the counterweight sections before moving, you have to now rig these sections again.

• On the RCL display, enter the counterweight combination to which you have to unrig (e.g. 95 t) (e.g. 209 439 lbs).

• Rig the relevant counterweight parts with an auxiliary crane. Procedure

à operating instructions.

2013.04.25

for rigging;

8 - 36

3 112 978 en

MWL operating instructions GMK 6400

9 9

Operation with heavy load lattice extension and MWL

9.1

Further rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

3

9.1.1 9.1.2

Rigging for operation with heavy load lattice extension. . . . . . . . . . . . . . . . . . . 9 Unrigging after operation with the heavy load lattice extension . . . . . . . . . . . . 9 -

3 4

9.2

Operation with braced boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

5

9.2.1 9.2.2 9.2.3

CHECKLIST: Putting the boom system into the operating condition . . . . . . . . 9 CHECKLIST: Putting the boom system into rigging mode . . . . . . . . . . . . . . . . . 9 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

5 6 7

9.3

Operation with MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

9

9.3.1 9.3.2

Putting the boom system into the operating condition. . . . . . . . . . . . . . . . . . . . 9 - 9 Putting the boom system into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11

9.4

Rigging mode with unbraced boom system and raised MWL . . . . . . . . . . . . . . . 9 - 13

9.5

Turning loads with the heavy load lattice extension. . . . . . . . . . . . . . . . . . . . . . . 9 - 15

9.5.1 9.5.2 9.5.3

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16 Setting the RCL for turning the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17 Turning a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 18

9.6

Driving with rigged crane and rigged heavy load lattice extension with rigged MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21 Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21 Rigging modes for moving and axle loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26

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9.6.1 9.6.2 9.6.3

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL

9

Operation with heavy load lattice extension and MWL

G

Risk of accidents if the safety information is ignored.

For operation of the heavy load lattice extension with MWL all the warnings in the lattice extension operating manual apply.

This chapter merely supplements the lattice extension operating manual with additional information required when operating the heavy load lattice extension together with the MWL.

This chapter provides you with information on the further procedure for operation using the heavy load lattice extension with MWL after rigging of the MWL. Section Further rigging work – The section contains information on the further rigging procedure and on preparation for rigging for operation with the heavy load lattice extension and MWL. Section Operation with braced boom system – The section contains all the information required for setting the RCL, telescoping with the MWL rigged, folding in and out and bracing the boom system with heavy load lattice extension.

Section Operation with MWL set down – The section contains all the information required on operation of the heavy load lattice extension when the MWL is rigged but neither raised nor braced.

Section Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

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– The section contains the boom positions required for driving the truck crane with the MWL rigged, and the axle loads which apply in this case.

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9-1

Operation with heavy load lattice extension and MWL

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9-2

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.1 Further rigging work

9.1

Further rigging work

9.1.1

Rigging for operation with heavy load lattice extension

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. The MWL has been rigged as described in the chapter Rigging and unrigCHECKLIST: Rigging the MWL, p. 5 - 1. ging the MWL;

à

2. Check on the relevant lifting capacity table whether the rigging mode to be set can only be rigged with the superstructure positioned to the rear; p. 1 - 15. Turn the superstructure to the position 0° to the rear if necessary.

à

3. Rig the required heavy load lattice extension as described in the Lattice extension operating manual.

4. Shift the deflection sheaves from the lower head sheave axle onto the p. 7 - 16. bracing arm; The bracing arms are mounted on the foot section.

à

5. Put the boom system into the operating condition required: – For operation with braced boom system;

à p. 9 - 9.

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– For operation with MWL set down;

à p. 9 - 5,

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9-3

Operation with heavy load lattice extension and MWL 9.1 Further rigging work

9.1.2

Unrigging after operation with the heavy load lattice extension 1. Put the boom system into the rigging mode required: – After operation with braced boom system; – After operation with MWL set down;

à p. 9 - 6,

à p. 9 - 11.

2. The current rigging mode for operation with the heavy load lattice extension is entered on the RCL.

3. Shift the deflection sheaves from the bracing arms onto the lower head p. 7 - 17. sheave axle;

à

4. Rig the heavy load lattice extension as described in the lattice extension Lattice extension operating manual. operating manual;

à

à CHECKLIST: Unrigging the MWL,

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5. To continue unrigging the MWL; p. 5 - 7.

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.2 Operation with braced boom system

9.2

Operation with braced boom system This section only describes operation with heavy load lattice extension and braced boom system, which enables increased lifting capacity.

For operation with the MWL rigged but not raised; set down, p. 9 - 9.

9.2.1

à Operation with MWL

CHECKLIST: Putting the boom system into the operating condition

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. Select the actual rigging mode for operation with heavy load lattice extension and MWL on the RCL or set the corresponding RCL code as Setting the RCL, p. 9 - 7. per the lifting capacity table;

à

2. Telescope the main boom to the telescoping required for operation according to the lifting capacity table. Telescoping is performed in the same way as for operation with the main boom without heavy load latTelescoping with rigged MWL, p. 6 - 7. tice extension;

à

3. Fold out both gantry masts. Folding out is performed in the same way as for operation with the main boom without heavy load lattice extension; Folding the gantry masts out/in, p. 6 - 9.

à

4. Derrick the main boom to the bracing angle required and brace the boom system. Derricking and bracing is performed in the same way as for operation with the main boom without heavy load lattice extension; Bracing the boom system, p. 6 - 11.

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à

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9-5

Operation with heavy load lattice extension and MWL 9.2 Operation with braced boom system

9.2.2

CHECKLIST: Putting the boom system into rigging mode

H

This checklist is not equivalent to the complete operating instructions. It is accompanied by operating instructions which are referred to in cross-references.

Observe the warnings and safety instructions contained.

1. The truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal.

2. The current rigging mode for operation with the heavy load lattice extension and MWL has been entered on the RCL; Setting the RCL, p. 9 - 7.

à

3. Set down the load; other than the hook block, no load may be raised.

4. Check on the relevant lifting capacity table whether the rigging mode to be set can only be rigged with the superstructure positioned to the rear; p. 1 - 15. Turn the superstructure to the position 0° to the rear if necessary.

à

5. To unlock the MWL, derrick the main boom to the bracing angle; Derricking to the bracing angle, p. 6 - 11.

à

à p. 6 - 14.

7. Fold in the gantry masts; à Folding the gantry masts out/in, p. 6 - 9.

8. Retract the main boom completely; à Telescoping with rigged MWL, 6. Unlocking the winches;

p. 6 - 7.

9. Slew the superstructure into the position for unrigging (preferably to the rear) and lower the main boom to the horizontal.

à Unrigging after operation with the

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10. To continue unrigging the MWL; heavy load lattice extension, p. 9 - 4.

9-6

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.2 Operation with braced boom system

9.2.3

Setting the RCL The current rigging mode for operation with the heavy load lattice extension ha been entered on the RCL. The MWL is then entered into this rigging mode.

The Enter rigging mode submenu shows the rigging mode entered, e.g.: – Counterweight combination 95 t (209 439 lbs), – Heavy load lattice extension 7.5 m (25 ft), 42°, – Outrigger span of 8.70 x 8.50 m (28.5 x 27.9 ft), – Slewing range ±180° The display (3) shows the corresponding RCL code, e.g. 3702.

The display (1) shows a truck crane with heavy load lattice extension.

• Press the button beside the symbol Input MWL (2) once.

The button is only active when the MWL is in the raised to 90° position:

H

If it is not permissible to operate the MWL with the rigging mode shown, there is no change on the display.

If operation with the MWL is permissible with the rigging mode shown: – the symbol (2) is shown in green, – the display (1) shows a truck crane with heavy load lattice extension and MWL, – the display (3) indicates the corresponding RCL code for operation with MWL, e.g. 4702.

• Confirm the selected rigging mode (Press button (4) 2x).

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9-7

Operation with heavy load lattice extension and MWL 9.2 Operation with braced boom system

The submenu RCL monitoring now shows the selected rigging mode with MWL. The display (1) shows the load of the rigging programme for the current rigging mode as per the lifting capacity table, e.g. 5.0 t (11 000 lbs).

The RCL only enables the increased load bearing capacities for operation with MWL when the MWL is braced.

à Error messages on

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If error messages occur; the RCL, p. 10 - 7.

9-8

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.3 Operation with MWL set down

9.3

Operation with MWL set down This section only describes operation with the heavy load lattice extension and the MWL set down. The boom system is not braced and increased lifting capacity will not be enabled.

9.3.1

Putting the boom system into the operating condition This section assumes that the MWL has been rigged as described in the checklist Rigging the MWL for operation with MWL set down.

If previously operated with the boom system braced, check that the following conditions are met.

– the deflection sheaves have been disconnected at the fastening point; Connecting/detaching the deflection sheaves to/from the lower head sheave axle, p. 5 - 49.

Raising/setting down the MWL, p. 5 - 51.

– the MWL has been set down;

à

à

Setting the RCL

For operation with the MWL set down, you must enter the current rigging mode for operation with the heavy load lattice extension without MWL on the RCL.

• Enter the current rigging mode.

For operation with MWL set down: – the display (1) must show a truck crane with heavy load lattice extension and without MWL and – the display (3) must show an RCL code for operation with the main boom, e.g. 3602.

• Confirm the selected rigging mode (Press button (4) 2x).

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The symbol (2) is shown in grey when the MWL is set down and the button next to the symbol is not active.

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9-9

Operation with heavy load lattice extension and MWL 9.3 Operation with MWL set down

The RCL now takes into account the Lifting capacity table corresponding to the RCL code displayed for operation with the heavy load lattice extension.

When the MWL is set down, the values specified in the lifting capacity tables are reduced.

The reduced values are shown directly on the display (1).

To calculate these values for operations planning lifting capacity tables.

à

H

The display (1) only shows the reduced values if the MWL is connected electrically. Otherwise, the values from the lifting capacity tables will be shown – however, the reduced values still apply for shut-down of the system.

If error messages occur;

Telescoping

G

Telescoping with the MWL set down is performed in the same way as for operation with heavy load lattice extension without MWL. Risk of damage to the side head sheaves and guy ropes.

Make sure that the deflection sheaves are disconnected at the side fastening points and have been pulled into the guides before you telescope the main boom with the MWL set down. This way you prevent damage to the deflection sheaves or the guy ropes when telescoping.

Operation of the power units when operating with the heavy load lattice extension with the MWL set down is the same as for operating with the heavy load lattice extension without MWL; Lattice extension operating manual GMK 6400 – heavy load lattice extension.

à

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Operation with the heavy load lattice extension

à Error messages on the RCL, p. 10 - 7.

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.3 Operation with MWL set down

9.3.2

Putting the boom system into rigging mode Operation of the power units with the MWL set down is performed in the same way as when operating with the heavy load lattice extension without MWL; Lattice extension operating manual.

à

This section assumes the following: – the truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal – the actual rigging mode for operation with the heavy load lattice extension is entered on the RCL.

• Set down the load.

• Check on the relevant lifting capacity table whether the rigging mode to be set can only be rigged with the superstructure positioned to the rear; p. 1 - 15. Turn the superstructure to the position 0° to the rear if necessary.

à

• Fully retract the main boom.

• Slew the superstructure into the position for unrigging the heavy load lattice extension and derrick the main boom into the horizontal position.

à Unrigging after operation with the heavy

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To continue unrigging the MWL; load lattice extension, p. 9 - 4.

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9 - 11

Operation with heavy load lattice extension and MWL 9.3 Operation with MWL set down

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9 - 12

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.4 Rigging mode with unbraced boom system and raised MWL

9.4

Rigging mode with unbraced boom system and raised MWL The rigging mode with rigged heavy load lattice extension and raised MWL with unbraced boom system is not for use when telescoping.

As long as the MWL is not braced, the RCL only enables the lifting capacity of the empty hook curve.

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G

Risk of overturning in an impermissible operating mode when RCL is bypassed.

Operation with the heavy load lattice extension is not permitted with the MWL raised and the boom system unbraced.

Do not under any circumstances override the RCL in this mode in order to raise loads the weight of which exceeds the values of the empty hook curve.

This way you prevent the truck crane from overturning.

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9 - 13

Operation with heavy load lattice extension and MWL 9.4 Rigging mode with unbraced boom system and raised MWL

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9 - 14

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

9.5

Turning loads with the heavy load lattice extension For turning loads;

G G

Risk of accidents due to overload.

You must only lift a load with two hooks if you adhere to the following specifications and the instructions and figures in the lattice extension operating manual.

If these instructions are not adhered to, accidents may occur due to individual components of the truck crane being overloaded. The RCL then no longer provides protection.

Two-hook operation when operating with the MWL is also permitted in conjunction with the heavy load lattice extension.

Risk of accidents due to overload.

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

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

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H

à lattice extension operating manual.

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9 - 15

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

9.5.1

Prerequisites The following description requires that – the main hoist rope has been reeved on the main boom, – the auxiliary hoist rope has been reeved on the heavy load lattice extension, – the lifting limit switches for both hoists are connected, – the reeving on the main boom is equal to or greater than that on the heavy load lattice extension, – the MWL has been raised and braced, – the main boom has the required telescope status, – the gantry masts have been folded out, – the RCL code is set as per the lifting capacity table for the actual rigging status of the truck crane.

Risk of accidents due to overload.

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

The auxiliary hoist rope and the auxiliary hoist will become overloaded if this requirement is not met.

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S G

Risk of damage to the hoist rope When you reeve the auxiliary hoist rope on the main boom and reeve the main hoist rope on the heavy load lattice extension, the hoist ropes rub against each other and the auxiliary hoist rope is at an impermissible angle.

This results in damage to both hoist ropes.

9 - 16

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

9.5.2

Setting the RCL for turning the load For two-hook operation, on the RCL you must: – enter the current reeving values for the main and auxiliary hoists and – switch on both hoists.

à Lattice extension operating manual section Setting the RCL for turning loads.

H

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

For operation with MWL:

• Select the current rigging mode with the heavy load lattice extension rigged and MWL on the RCL or enter the respective RCL code as per the Lifting capacity table.

• Brace the boom system. Otherwise, only the rigging programme loads for

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the current rigging modes given in the Lifting capacity table is enabled.

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9 - 17

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

9.5.3

Turning a load Only ever perform load turning as it is described in this section.

G H H

Risk of accidents due to overload.

Keep the acceleration forces as low as possible when performing two-hook operation.

For this reason, move the load at the lowest possible speed.

If the load is on two hooks, there is slight differences in the actual load display. However, these deviations are still on the safe side as regards an RCL shut-down.

During the entire lifting process, the rigging mode with the heavy load lattice extension and braced boom system has to be entered on the RCL and displayed.

• First, only sling the load on the hook block of the heavy load lattice extension (rope of the auxiliary hoist).

• Lift the load completely off the ground with the heavy load lattice extension.

• Only now should you attach the load to the

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hook block of the main boom as well (main hoist rope).

9 - 18

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

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

• Slacken the hoist rope on the heavy load lattice extension until the load is only hanging from the hook block on the main boom.

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Turning the load has now been completed.

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9 - 19

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

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9 - 20

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

9.6

Driving with rigged crane and rigged heavy load lattice extension with rigged MWL This section describes how to move the truck crane with an installed counterweight, rigged heavy load lattice extension and rigged MWL. In addition to this section you must also adhere to the following: – Chapter Driving with a rigged truck crane in the Operating Instructions, – Section Driving with a rigged truck crane and rigged MWL, p. 6 - 25.

G G G 9.6.1

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.

Risk of overturning from 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 if your view of the truck crane is partially obstructed!

While driving, always stay in visual or radio contact with a banksman who can observe the parts which you cannot see.

Driving distance

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Please also adhere to the section Driving distance, p. 6 - 26.

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9 - 21

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

9.6.2

S Putting the truck crane into the rigging mode

Rigging modes for moving and axle loads Risk of damage to the axle lines!

Move the superstructure, the main boom and the heavy load lattice extension into the specified positions only. This prevents excessive strain on the axle lines.

One of the following tables shows the required rigging mode for the procedure for the currently rigged heavy load lattice extension. The rigging mode is defined by: – the position of the MWL, – the angle of the heavy load lattice extension, – the counterweight combination, – the position of the superstructure, – the telescope status and – the main boom angle.

• Set down the load. No load may be raised other than the hook block.

• Set down the MWL as necessary; à Setting down the MWL, p. 5 - 59.

• If necessary, set the angle of the boom extension required for driving;

à Lattice extension operating manual.

• Reeve larger hook blocks rather than just the permitted ones.

Permitted hook blocks, e.g. p. 9 - 24.

à 4 m (13 ft)-heavy load lattice extension,

• Enter the current counterweight combination or the counterweight combination to which you have to unrig on the RCL display (e.g. 95 t (209 439 lbs)).

• On the RCL display, enter the current rigging mode of the lattice extension: – the length and the angle of the rigged heavy load lattice extension (e.g. 7.5 m (25 ft) and 20°), – operation with MWL when MWL is raised.

• If necessary, use an auxiliary crane to unrig to the required counterweight

à Operating Instructions.

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

• Switch off the slewing gear; à Operating Instructions.

• Lock the superstructure; à Operating Instructions.

9 - 22

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MWL operating instructions GMK 6400

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combination;

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

• Derrick the main boom to the required angle for telescopic extension.

You can find the required main boom angle in the lifting capacity tables, in chapter Boom extension rigging table).

• Telescope the main boom to the required telescope status and lock the telescopic sections.

• Derrick the main boom to the position required.

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s

MWL operating instructions GMK 6400

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9 - 23

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

Main boom angle in °

Main boom position1)

0/0/0/0

15

vorne

11,5 (25,4)

23,0 (50,7)

0/0/0/0

82

hinten

9,5 (21,0)

24,5 (54,0)

0/0/0/0

15

vorne

13,0 (28,7)

21,5, (47,4)

0/0/0/0

82

hinten

11,5 (25,4)

23,0 (50,7)

vorne

17,0 (37,5)

23,5 (51,8)

abgelegt 20 aufgerichtet (90°)

/0/0/0 Data 88 not available15yet.

abgelegt 40 (88 100)

82

hinten

13,5 (29,8)

26,5 (58,4)

88 / 0 / 0 / 0

15

vorne

19,0 (41,9)

22,5 (49,6)

0/0/0/0

82

hinten

15,5 (34,2)

24,5 (54,0)

88 / 88 / 44 / 0

15

vorne

22,0 (48,5)

25,0 (55,1)

0/0/0/0

82

hinten

17,5 (38,6)

28,0 (61,8)

88 / 88 / 0 / 0

15

vorne

21,5 (47,4)

25,5 (56,2)

0/0/0/0

82

hinten

20,0 (44,1)

26,5 (58,4)

abgelegt 60 (132 200)

20 aufgerichtet (90°)

80,100, 120, 140, 160

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 60 t (132 200 lbs) abrüsten.

1)

2)

9 - 24

rear

0/0/0/0 20 aufgerichtet (90°)

front

Rear:

indicated slewing angle 0°

Front:

indicated slewing angle 180°

Front:

on each the first and second axle line

Rear:

on each of the 3rd to 6th axle line

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MWL operating instructions GMK 6400

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20 (44 000)

Axle load2) in t (x 1000 lbs)

Telescoping Telescopic section I/II/III/IV

Position of the MWL

The specified axle loads apply for reeved 32 t hook blocks (weight 620 kg (1 370 lbs)).

Lattice extension inclination in °

Rigged counterweight in t (lbs)

4 m (13 ft)-heavy load lattice extension

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

The specified axle loads apply for reeved 32 t hook blocks (weight 620 kg (1 370 lbs)).

Main boom angle in °

Main boom position1)

0/0/0/0

15

vorne

12,5 27,6

22,5 49,6

0/0/0/0

82

hinten

9,0 (19,9)

25,0 (55,1)

0/0/0/0

15

vorne

14,5 (32,0)

21,0, (46,3)

0/0/0/0

82

hinten

11,5 (25,4)

23,5 (51,8)

Data 88 not / 0 /available 0/0 15yet. vorne

19,0 (41,9)

22,5 (49,6)

abgelegt 20 (44 000)

20 aufgerichtet

abgelegt 40 (88 100)

80,100, 120, 140, 160

20

rear

82

hinten

13,5 (29,8)

27,0 (59,5)

88 / 0 / 0 / 0

15

vorne

20,5 (45,2)

21,5 (47,4)

0/0/0/0

82

hinten

15,5 (34,2)

25,0 (55,1)

88 / 88 / 0 / 0

15

vorne

22,0 (48,5)

25,5 (56,2)

88 / 44 / 0 / 0

82

vorne

19,5 (43,0)

27,0 (59,5)

0/0/0/0

82

hinten

19,5 (43,0)

27,0 (59,5)

20

abgelegt

front

0/0/0/0

aufgerichtet

60 (132 200)

Axle load2) in t (x 1000 lbs)

Telescoping Telescopic section I/II/III/IV

Position of the MWL

Lattice extension inclination in °

Rigged counterweight in t (lbs)

7.5 m (25 ft)-heavy load lattice extension

aufgerichtet

Fahren mit aufgerüstetem Mobilkran nicht zulässig.

Gegengewicht-Kombination auf 60 t (132 200 lbs) abrüsten.

1)

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2)

MWL operating instructions GMK 6400

Rear:

indicated slewing angle 0°

Front:

indicated slewing angle 180°

Front:

on each the first and second axle line

Rear:

on each of the 3rd to 6th axle line

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9 - 25

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

9.6.3

Driving

Before driving

• Check the tyre pressure and the wind speed;

à Operating Instructions.

• Check whether

à

– the slewing gear is switched off; Operating Instructions.

– the superstructure is locked; Operating Instructions.

à

• Place the truck crane on the wheels; à 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.

Driving from the driver's cab

• Engage the lowest starting gear; à 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 Operating Instructions.

If required, you can – switch on the longitudinal differential locks, – Switch on the transverse differential locks While driving

• Drive only at the lowest possible speed, maximum 1.5 km/h (1 mph).

• The turning radius should be as large as possible when driving around corners!

• Steer the truck crane only when it is rolling and avoid sudden steering movements.

Danger of overturning when switching on the suspension!

The suspension must be deactivated (locked) as long as the rigged truck crane is on wheels.

When switching on the suspension, the suspension cylinders would suddenly be pressed together and damaged, and the truck crane could overturn.

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S G

Risk of damage to the steering linkage!

The steering linkage can be damaged if the steering is operated while the vehicle is stationary.

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MWL operating instructions GMK 6400

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

After driving

• Switch the separate steering off after driving; à Operating Instructions.

• Apply the parking brake; à Operating Instructions.

Set the truck crane down on the outrigger span required for the scheduled Operating Instructions. operation;

à

If necessary, rig the counterweight sections

If you have rigged the counterweight sections before moving, you have to now rig these sections again.

• On the RCL display, enter the counterweight combination to which you have to unrig (e.g. 95 t) (e.g. 209 439 lbs).

• Rig the relevant counterweight parts with an auxiliary crane. Procedure

à operating manual.

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for rigging;

MWL operating instructions GMK 6400

3 112 978 en

9 - 27

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

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9 - 28

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MWL operating instructions GMK 6400

10 10

Errors during operation with the MWL

10.1

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

2

10.1.1

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

2

10.2

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

3

Errors during operation with the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3 Errors when operating with the hand-held control . . . . . . . . . . . . . . . . . . . . . . 10 - 6 Error messages on the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 7 Error messages on the crane control display. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10

10.3

Operation with emergency programme switched on . . . . . . . . . . . . . . . . . . . . . 10 - 11

10.3.1 10.3.2

Operating the MWL in the emergency programme. . . . . . . . . . . . . . . . . . . . . . 10 - 11 Telescoping in the emergency programme with a rigged MWL . . . . . . . . . . . 10 - 15

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MWL operating instructions GMK 6400

Errors during operation with the MWL

10

Errors during operation with the MWL This chapter supplements the chapter Errors during crane operation in the operating instructions with the following points: – Electrical system – Troubleshooting – Error messages on the RCL display

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– Error messages on Crane control display

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10 - 1

Errors during operation with the MWL 10.1 Electrical system

10.1

Electrical system

10.1.1

Fuses In the distribution box on the right-hand side at the turntable there is an extra fuse group.

• Open the cover (1).

• Open the distribution box behind it.

The fuse group F 7 is for the electrical system of the MWL. The designations 1 to 8 in the tables correspond to the order from top to bottom (fuse 1 is always the top fuse).

Designation in the electrical circuit diagram: F 7

Amperage (A)

Function

1

20

ESX 5 supply

2

10

ESX 5 supply

3

5

MWL and luffing jib button

4

20

ESX 5 supply, CAN bus

5

10

not assigned

6

20

not assigned

• Adhere to the instructions for a fuse change; à Operating Instructions GMK 6400.

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• Close the distribution box and cover after checking (1).

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MWL operating instructions GMK 6400

Errors during operation with the MWL 10.2 Troubleshooting

10.2

Troubleshooting

10.2.1

Errors during operation with the MWL

H

Generally all functions of the MWL are disabled when a load other than the hook block is raised, or when operation with MWL has not been selected on the RCL.

Error

Cause

Remedy

The submenu Operation-MWL cannot be called up from the main menu.

The MWL is not electrically connected. The Operation-MWL submenu symbol is shown in light grey.

Check whether the electrical connection is properly established; p. 5 - 42.

The current programme version of the crane control is not equipped for operation with MWL. The Operation-MWL submenu symbol is not displayed.

The crane control requires another programme version; inform Manitowoc Crane Care.

The supply line to the ESX 5 control unit (in the right-hand gantry mast) is broken or the ESX 5 control unit is faulty.

Check the supply line as necessary and inform Manitowoc Crane Care.

No function when: locking/unlocking winches, winding/winding off winches, raising/setting down the MWL, folding out/folding in the gantry masts

The hydraulic or electrical connections are not established properly.

Establish the hydraulic conp. 5 - 42) and nection ( the electrical connection p. 5 - 41) properly. (

Winches cannot be unlocked

A load other than the hook block is raised.

Set down the load.

Winches cannot be locked

The boom system is braced, the winches are already locked.

Winches cannot be wound or unwound

The winches are locked.

à

à

à

Unlock the winches; p. 5 - 54 or p. 5 - 61

à

à

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10 - 3

Errors during operation with the MWL 10.2 Troubleshooting

Error

Cause

Remedy

The MWL cannot be locked on the main boom

The hydraulic or electrical connections are not established properly.

Establish the hydraulic connection ( p. 5 - 42) and the electrical connection p. 5 - 41) properly. (

The position of the gantry masts to the holder frame is not correct.

Check the position, adjust if p. 5 - 43. necessary;

The MWL cannot be unlocked on the main boom

As The MWL cannot be locked on the main boom and the locking pins are not loose.

As The MWL cannot be locked on the main boom and loosen the locking pins; à p. 5 - 48.

The MWL cannot be set down.

The boom system is braced.

The gantry masts are not folded in completely.

The main boom is at an angle over 5°

The gantry masts cannot be folded out or in.

The boom system is braced.

The MWL is not raised to the end position 90°.

The maximum permissible rope force was exceeded because the winches are locked.

The following functions are disabled and the corresponding displays show the error message in purple:

There is a logic error. E.g. the end statuses locked and unlocked are signalled simultaneously.

– Locking/unlocking the winches (c d)

Or there is an electrical error on the corresponding proximity switches.

à

à

à

Unlock the winches;

à p. 5 - 62 or à p. 5 - 54 Fold in the gantry masts completely; p. 5 - 64 or p. 6 - 9

à

à

Derrick the main boom to an angle under 5° Unlock the winches;

à p. 5 - 62 or à p. 6 - 15 MWL Raise the MWL to the end position 90°; p. 5 - 58.

à

Unlock the winches;

à p. 5 - 62 or à p. 6 - 15 Manitowoc Crane Care

Inform Unrig the MWL with the emergency programme as p. 10 - 11 necessary.

à

– Folding the gantry masts in/out (l n) – MWL raising/setting down (m) One or both gantry masts are not folded in completely:

Fold in the gantry masts completely; p. 6 - 9.

One or both winches are unlocked.

à p. 6 - 14.

The MWL is not raised to the end position 90°.

10 - 4

3 112 978 en

à

Lock the winches;

MWL Raise the MWL to the end position 90°; p. 5 - 58.

à

MWL operating instructions GMK 6400

2013.04.25

The main boom cannot be telescoped.

Errors during operation with the MWL 10.2 Troubleshooting

Error

Cause

Remedy

The main boom cannot be derricked, the derricking gear display shows red arrows

The MWL is in an intermediate position (p).

MWL Move into the raised to 90° position (X) or the set down below 5° position (q) p. 5 - 58, p. 5 - 59.

MWL cannot be braced.

à

(p) (X) The main boom is in an impermissible telescope status.

à

Move the main boom into a telescoping position which is permitted for operation with the MWL; lifting capacity table.

à The main boom is not at the required bracing angle.

Derrick the main boom to the bracing angle shown on the Bracing angle set value p. 6 - 11. display;

à

The telescoping mechanism does not meet all the requirements for bracing

Check the following and correct if necessary: The telescopic sections are locked.

The telescoping cylinder is locked.

The telescopic section has been set down.

The MWL is not raised to the end position 90°.

MWL Raise the MWL to the end position 90°; p. 5 - 58.

The gantry masts are not folded in or out completely.

Fold out the gantry masts completely; p. 6 - 9.

Operation with MWL has not been selected on the RCL.

Select operation with MWL on the RCL; p. 6 - 4.

The bracing procedure was not completed. The bracing status display shows the error symbol in purple (k).

During the bracing procedure an error was detected, and the procedure was aborted as a result.

Unlock the winches and repeat the bracing procedure. If the error occurs again, contact Manitowoc Crane Care.

The RCL shuts down due to overload even though the maximum lifting capacity according to the load capacity chart has not been exceeded.

Operation with MWL has not been selected on the RCL .

Select operation with MWL on the RCL; p. 6 - 4.

The MWL is raised but the boom system is not braced.

Brace the boom system; p. 6 - 11.

During operation with MWL set down, operation with MWL is still selected on the RCL.

Select operation without MWL on the RCL; p. 6 - 4.

à

à

à

à

à

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à

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10 - 5

Errors during operation with the MWL 10.2 Troubleshooting

10.2.2

Errors when operating with the hand-held control The following diagnostic chart applies for both hand-held controls.

Error

Cause

Remedy

CAN indicator lamp flashes or stays off after connecting the hand-held control.

A bridging plug has been pulled out of another socket.

Insert the bridging plug and secure it with a collar nut; Operating Instructions GMK 6400.

Error on the control system

Manitowoc Crane Care Inform

Fuse F 1/2 OW defective

Check the fuses, replace them as necessary; Operating Instructions GMK 6400 – Malfunctions during crane operation.

The crane control emergency stop switch or the emergency stop switch on the hand-held control has been pressed.

à

à Operating Instructions

GMK 6400 – Malfunctions during crane operation.

Another function has been pre-selected

Pre-select the desired function

Error on the control system

Manitowoc Crane Care Inform

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Pre-selected function cannot be performed

à

10 - 6

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MWL operating instructions GMK 6400

Errors during operation with the MWL 10.2 Troubleshooting

10.2.3

Error messages on the RCL This section only shows the error messages and possible remedies for truck cranes which are equipped with the MWL. If other error messages are displayed:

à Operating Instructions GMK 6400 Malfunctions – Malfunctions during crane operation

à Lattice extension operating manual – Malfunctions Error message display – the error code (3) – the symbols for 4

the error group

5

the faulty component

6

the type of error

– possibly the error location (1) – the respective places (2) flash in red.

• Check whether the Error codes tables contain the error. This is where you will find information on how to remedy errors.

If other error codes are shown, contact Manitowoc Crane Care.

Error group 1, sensor system Error code 1.

25.

1

Cause

Remedy

Sensor A left not reacting (load cell Left-hand winch)

Check the supply line; p. 10 - 9.

If supply line is OK, notify Manitowoc

à

Crane Care

1.

25.

2

Measured values are no longer updated.

Switch the ignition off and back on again. Notify Manitowoc Crane Care if the error is displayed again.

1.

25.

6

Error in the data transmission

Switch ignition off and back on again, p. 10 - 9, if Check the supply line; the error is displayed again, Manitowoc Crane Care inform

à

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10 - 7

Errors during operation with the MWL 10.2 Troubleshooting

Error group 1, sensor system Error code 1.

26.

1

Cause

Remedy

Sensor B left not reacting (load cell Right-hand winch)

Check the supply line; p. 10 - 9.

If supply line is OK, notify Manitowoc

à

Crane Care

1.

26.

2

Measured values are no longer updated.

Switch the ignition off and back on again. Notify Manitowoc Crane Care if the error is displayed again.

1.

26.

6

Error in the data transmission

Switch the ignition off and back on again, and check supply line. p. 10 - 9, notify Manitowoc Crane Care if the error is displayed again.

Sensor A right not reacting (load cell Left-hand winch)

Check the supply line; p. 10 - 9.

If supply line is OK, notify Manitowoc

1.

27.

1

à

à

Crane Care

1.

27.

2

Measured values are no longer updated.

Switch the ignition off and back on again. Notify Manitowoc Crane Care if the error is displayed again.

1.

27.

6

Error in the data transmission

Switch the ignition off and back on again, and check supply line. p. 10 - 9, notify Manitowoc Crane Care if the error is displayed again.

Sensor B right not reacting (load cell Right-hand winch)

Check the supply line; p. 10 - 9.

If supply line is OK, notify Manitowoc

1.

28.

1

à

à

Crane Care

1.

28.

2

Measured values are no longer updated.

Switch the ignition off and back on again. Notify Manitowoc Crane Care if the error is displayed again.

1.

28.

6

Error in the data transmission

Switch the ignition off and back on again, and check supply line. p. 10 - 9, notify Manitowoc Crane Care if the error is displayed again.

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à

10 - 8

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MWL operating instructions GMK 6400

Errors during operation with the MWL 10.2 Troubleshooting

5.

03.

5

Inclination of lattice extension too small

During operation: Lower the luffing jib When rigging à Place the luffing jib on the floor during rigging, p. 10 - 9.

Check the supply line

The measuring plate sensors are located on the winches.

1 Plug connection for sensor A, right-hand winch 2 Plug connection for sensor B, left-hand winch

• To check the lines, follow the lines from the plug connections to the sensors or vice versa.

Place the luffing jib on the floor during rigging

When unrigging:

• Do not lower it any further.

• Acknowledge the error message.

• Lower the auxiliary hoist so that the track rollers on the head touch the ground. If the ground is not stable enough, place approx. 2 m long stable planks to the front under the track rollers.

• Lower the main boom and lower the auxiliary hoist at the same time.

The track rollers move over the planks.

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10 - 9

Errors during operation with the MWL 10.2 Troubleshooting

When rigging:

• Do not raise it any further.

• Acknowledge the error message.

• Lower the auxiliary hoist so that the track rollers on the head remain on the ground. If the ground is not stable enough, place approx. 2 m long stable planks to the rear under the track rollers.

• Raise the main boom and lower the auxiliary hoist at the same time.

The track rollers move over the planks.

Only raise the main boom far enough so that the head moves approx. 2 m to the rear.

• Do not luff the luffing jib anymore.

Raise the main boom.

10.2.4

Error messages on the crane control display When operating with the MWL error messages from the crane control are displayed in the same way as when operating without Operating Instructions GMK 6400; MWL – Error messages on the crane control display.

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à

10 - 10

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MWL operating instructions GMK 6400

Errors during operation with the MWL 10.3 Operation with emergency programme switched on

10.3

Operation with emergency programme switched on When the MWL is rigged the telescoping emergency programme can be switched on. This emergency programme is provided for two scenarios: – For unrigging the MWL when the MWL cannot be operated due to an electrical error (e.g. when the folded out message is detected when the gantry masts are folded in – in this case the MWL can no longer be set down).

– For unrigging the truck crane when the telescoping mechanism can only be operated in the emergency programme due to an electrical error.

In both cases, special conditions apply. For this reason, observe the information in the following chapter before calling up the emergency programme.

10.3.1

Operating the MWL in the emergency programme if the MWL can no longer be operated due to an electrical error, in most cases the symbol (1) or (2) is shown in purple.

In this case, you can only control some functions of the MWL by switching on the Telescoping emergency programme.

Switching on the emergency programme

S

Risk of damage when emergency programme is switched on Be sure that all necessary requirements are fulfilled before you perform a function in the emergency programme. The crane control is not monitored.

All functions are carried out immediately and unconditionally.

ö

• If required, open the main menu ( • Press the button (1) once.

).

The Settings/Displays submenu is opened.

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10 - 11

Errors during operation with the MWL 10.3 Operation with emergency programme switched on

• Press the right-hand dead man's switch (3).

• Additionally press the button (2) once – symbol (4) appears.

• Press the buttons (1) in the order:

ÆÅÆÇ

The symbols (5) confirm the entry.

If your input was incorrect, all the symbols (5) go out and you need to repeat the input.

You can cancel the entry at any time using button (6).

After correct input, the symbol (1) is displayed – the emergency programme Telescoping starts.

The emergency programme stays switched on for about 360 seconds.

S

Risk of damage to the telescoping mechanism!

Do not telescope in the emergency programme if there is no error on the telescoping mechanism. In the emergency programme the telescoping mechanism is not monitored by the crane control and you can execute functions that would damage the telescoping mechanism.

If there is no error on the telescoping mechanism but you still need to telescope, abort the emergency programme for telescoping by: – waiting until the emergency programme is switched off automatically (360 seconds) or – switching off the ignition.

H

When you abort the emergency programme by switching off the ignition, you have to re-enter the telescope diagram after restarting.

Operating Instructions GMK 6400.

à

• Switch to the Operation-MWL submenu.

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As long as the emergency programme is switched on, the display (1) is shown in the Operation-MWL submenu and in the Rigging-MWL submenu.

10 - 12

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MWL operating instructions GMK 6400

Errors during operation with the MWL 10.3 Operation with emergency programme switched on

The functions are only enabled if the symbol (1) is shown in grey.

• If the symbol (1) in shown in green, press the button (2) once.

The symbol (1) is now shown in grey and the functions are enabled in the emergency program.

Operating the MWL

When the emergency programme is switched on, the MWL can only be set down at low speed.

In the submenu Operation-MWL The following buttons are not active in emergency operation: – the button (2) – the buttons (4)

The following buttons are active with no change to their function in emergency operation: – the buttons (3) – the buttons (1) (to a limited extent)

When the buttons (1) are pressed, only unlocking or locking is performed. You may need to provide manual help for the process in the Rigging-MWL submenu: – If unlocking is not performed, you will need to wind the winches a little to relieve the locking units; buttons (1), (2).

– If locking is not performed, you will need to wind or unwind the winches a little so that the teeth on the locking unit can engage; button (1), (3) or (2), (4).

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10 - 13

Errors during operation with the MWL 10.3 Operation with emergency programme switched on

In the submenu Rigging-MWL The following buttons are active with no change to their function in emergency operation: – the buttons (3) – the buttons (2) – the buttons (1) (to a limited extent)

2013.04.25

When the buttons (1) are pressed, only unlocking or locking is performed. You may need to help the process manually as described above; button (2).

10 - 14

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MWL operating instructions GMK 6400

Errors during operation with the MWL 10.3 Operation with emergency programme switched on

10.3.2

S

Telescoping in the emergency programme with a rigged MWL Risk of damage when emergency programme is switched on All the specifications and safety instructions in the operating manual (included in the scope of delivery) are authoritative for operation of the telescoping mechanism in the emergency programme; Operating Instructions GMK 6400 chapter Emergency operations and programmes.

This section only contains additional information which must be observed when the MWL is rigged before telescoping in the emergency programme.

à

The telescoping emergency programme is switched on in the same way as when operating without MWL; Switching on the emergency programme, p. 10 - 11.

à

• Adhere the following points about the specifications in the Operating Instructions (included in the scope of delivery) before telescoping in the emergency program.

When retracting

G

When retracting in the emergency programme, the winches on the gantry masts do not automatically follow. Thus the guy ropes sag.

Danger due to slack rope!

Pay attention that the guy ropes do not slacken to the point where there is slack rope when winding.

• When retracting, pay attention to the guy ropes. Stop the retraction process in good time and wind the winches so that the guy ropes are taut (buttons (1) and (2)).

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10 - 15

Errors during operation with the MWL 10.3 Operation with emergency programme switched on

When extending

Carry out the Extending function in the emergency programme only if it is absolutely necessary. The winches on the gantry masts do not automatically follow. The guy ropes are therefore tensioned.

In order to prevent the guy ropes from becoming overloaded, the rope forces are monitored during the extending process. As soon as the maximum permissible rope force has been reached, the crane control switches off the extension process.

In order to be able to continue extending:

• Wind off the winches so that the guy ropes sag slightly (buttons (1) and

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(2)) .

10 - 16

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MWL operating instructions GMK 6400

11 11

Maintenance

11.1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

2

11.2

Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

4

11.3

Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

7

11.3.1

Use of lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

7

11.4

Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

9

Changing the guy ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 25

11.5

Spare parts required for maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 31

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11.4.14

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MWL operating instructions GMK 6400

Maintenance

11

Maintenance Adhere to the following sections from the Maintenance Manual: – 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 specified maintenance plans apply in addition to the maintenance plans with the same name in the Maintenance Manual GMK 6400.

– The operating hours on the MWL are displayed in the operating hours submenu; Operating Instructions GMK 6400,

à

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

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– Adhere to the valid national regulations for periodic inspections

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11 - 1

Maintenance 11.1 Cleaning

11.1

Cleaning

H

Follow the instructions for cleaning work with high-pressure cleaners in the 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

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.

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G

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

11 - 2

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MWL operating instructions GMK 6400

Maintenance 11.1 Cleaning

• Provide protection for the following electrical parts during cleaning work: 1 Guy rope on the winch drum 2 Angle sensor 3 Proximity switch (interlocking) 4 Plug connection for load cells 5 Valve blocks 6 Control unit (opening at the bottom in the gantry mast) 7 Angle sensor 8 Plug in the dummy sockets 9 Angle sensor 10 Hydraulic connections 11 Switch box

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12 Various plug connections (not shown)

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11 - 3

Maintenance 11.2 Maintenance plans

11.2

Maintenance plans

11.2.1

Maintenance plan D

D

Maintenance work on the SUPERSTRUCTURE: daily/before commissioning MWL

à p. 11 - 10 à p. 11 - 9

– Checking the guy ropes on the winch drum – Check the lubrication on the gear rims

11.2.2

Maintenance plan W

W

Maintenance work on the SUPERSTRUCTURE: weekly MWL – Checking the deflection sheaves – General control of the winch gears – Checking the oil level in the winch gears – Checking the end fastenings of the guy ropes1)

If the MWL has only been stored, inspection is required only every three months.

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1)

à p. 11 - 11 à p. 11 - 13 à p. 11 - 13 à p. 11 - 14

11 - 4

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MWL operating instructions GMK 6400

Maintenance 11.2 Maintenance plans

11.2.3

Maintenance plan M 3

M3

Maintenance work on the SUPERSTRUCTURE: every three months/ after 300 operating hours MWL

à p. 11 - 18 à p. 11 - 19 à p. 11 - 16 à p. 11 - 16

– Lubricating the winch gears – Lubricate gear rims – Lubricating the guy ropes – Lubricating other lubricating points

11.2.4

Maintenance plan M 6

M6

Maintenance work on the SUPERSTRUCTURE: every six months/ after 500 operating hours MWL

à p. 11 - 20

– Checking the condition of the guy ropes

11.2.5

Maintenance plan M 12

M 12

Maintenance work on the SUPERSTRUCTURE: every 12 months/ after 1000 operating hours MWL

à p. 11 - 23 à p. 11 - 22

– Changing the oil at the winch gears1) – Lubricating the locking units carry out at least once a year

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1)

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11 - 5

Maintenance 11.2 Maintenance plans

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11 - 6

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MWL operating instructions GMK 6400

Maintenance 11.3 Lubricants

11.3

Lubricants The list of lubricants in the maintenance instructions applies.

The GROVE part numbers for lubricants which you requires for maintenance of the MWL are shown in the respective sections.

Using the GROVE part number you can find the specification of the lubricant in the lubricant list in the maintenance manual.

11.3.1

Consec.

No.1)

8

Use of lubricant

Lubrication type

Application

Grease

Maintenance interval

other lubricating points

M3

Winch gear

M3

Locking units

M12 M3

9

Adhesive lubricating grease

Gear rims for the winches

6

Gear oil

Winch gear

Approximately 1.0 (0.45)

M12

The consecutive number is identical to the consecutive number from the list of lubricants in the maintenance manual.

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1)

Fill quantity in litres (gal)

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11 - 7

Maintenance 11.3 Lubricants

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11 - 8

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

11.4

Maintenance work

11.4.1

Check the lubrication on the gear rims

Prerequisites

– The MWL has been set down or raised or switched off in transport position.

D

If the MWL is raised: The engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

G Checking

Risk of crushing if the winches are operated inadvertently.

Shut down the engine and secure it to prevent unauthorised use before you check the lubrication on the gear rims. In this way you prevent being crushed by the rotating gear rim or flapping locking element.

• Make sure the aforementioned requirements have been met.

The gear rims (2) are located on the right-hand side on both winches and can be viewed from above and below.

• Check the lubrication on the gear teeth on the sprocket wheel (2) and the locking unit (1).

If the gear teeth: – are dry or – not covered with sufficient lubricant grease,

• Lubricate the gear rims; à p. 11 - 19.

• Check the gear teeth on the other side of the

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MWL in the same way.

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11 - 9

Maintenance 11.4 Maintenance work

D

11.4.2

Checking the guy ropes on the winch drum

Prerequisites

– The MWL has been set down or raised or switched off in transport position.

– If the MWL is raised: The engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

G Checking

Risk of accidents from unintentional rotation of the winch drum Shut down the engine and secure it against unauthorized use before you start work on the winch drums. The rotating winch drum can inflict serious crushing injuries!

• Make sure the aforementioned requirements have been met.

• Check the position of the guy rope on the winch drum (1).

– The rope must be wound evenly onto the rope drum.

– The turns on the drum must all be at an equal distance of between 0 to 2 mm (0.08 inch).

– The cross-over points must offset by approximately 180°.

The upper rope lines lie over the lower rope lines at the cross-over points.

• Check the position of the guy rope on the

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other winch in the same way.

11 - 10

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

11.4.3

Checking the deflection sheaves

Spare parts and tools

– Torque wrench for torque of 180 Nm (133 lbf ft).

Prerequisites

– The MWL has been raised.

W

– The crane engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

G Checking

Risk of accidents when winding the guy rope.

The rotating deflection sheave and the running guy rope can trap parts of the body and injure you. You must therefore keep at a distance from the sheave and the rope. Have a helper help you.

• Make sure the aforementioned requirements have been met.

• Slowly unwind the guy rope (1);

à Winding/unwinding the winches, p. 5 - 55.

In the process the deflection sheaves (3) rotates.

• Check the deflection sheave (3) for: – damage, wear and freedom of movement, – There must be no scores anywhere on the entire circumference of the base of the groove (2).

• Replace the deflection sheave as necessary.

• Stop the winch.

• Check that the bolts (4) are firmly in place; tightening torque 165 Nm (122 lbf ft).

• Remove the pin (5) form the connecting point.

• Check the pin (5) for damage, corrosion and deformation.

• Replace the pin (5) as necessary.

• Plug the pin (5) back into the connection point and secure it with the retaining pin.

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11 - 11

Maintenance 11.4 Maintenance work

• Slowly unwind the guy rope further.

• Check the deflection sheave (2) for: – damage, wear and freedom of movement, – There must be no scores anywhere on the entire circumference of the base of the groove (1).

• Replace the deflection sheave as necessary.

• Wind the guy rope so that the deflection sheave (1) is drawn into the guide (2); Winding/unwinding the winches, p. 5 - 55.

à

• Stop the winch when the gap is A approximately 150 mm (0.5 ft).

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• Check the deflection sheave (1) on the other side in the same way.

11 - 12

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

11.4.4

General control of the winch gears

Prerequisites

– The MWL has been set down or raised.

W

– The engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

• Make sure the aforementioned requirements have been met.

Checking

• Perform a visual inspection for leaks.

• If hydraulic oil or gear oil has been lost, check the oil levels and top up if necessary.

If damage cannot be rectified immediately or further damage is likely:

• Inform Manitowoc Crane Care or you repair crew.

11.4.5

Checking the oil level in the winch gears

Prerequisites

– The MWL is rigged or switched off.

W

– The engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

• Make sure the aforementioned requirements have been met.

Checking

H

The MWL must be level in the longitudinal direction, otherwise there is a false oil level.

• Check the oil level on the inspection glass (1). The hydraulic oil must be visible in the centre of the inspection glass.

• Check the oil level at the other winch in the same way.

If the oil level is too low:

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• Top up the oil; à p. 11 - 24.

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11 - 13

Maintenance 11.4 Maintenance work

11.4.6

Checking the end fastenings of the guy ropes

Spare parts and tools

– Torque wrench for 270 Nm (221.2 lbf ft).

Prerequisites

– The MWL is rigged or switched off in transport position.

Check at the gantry masts

• Make sure the aforementioned requirements have been met.

W

Holders and load cells are found are between the guy ropes and the gantry masts.

Fastening the rope ends

• Check the splice clamp (4) and the guy rope in the vicinity of the splice clamp for corrosion and deformation.

• Check the pin (3) for corrosion and deformation.

• Check that the cotter pin (2) fits tightly.

• Check the fastenings on the other gantry mast in the same way.

• Damaged parts must be replaced immediately.

Fastening the load cells

• Check the pins (1) for corrosion and deformation.

• Check that the cotter pins (2) fit tightly.

• Check the fastenings on the other gantry mast in the same way.

• Damaged parts must be replaced immedi-

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ately.

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

Check at the winch drums

S G

• Make sure the aforementioned requirements have been met.

The end fastening on the winch drum is a clamping device with 15 locking screws. The winches must be running for the inspection.

Risk of damage and danger from slack rope Do not draw the deflection sheave too high when you wind the winches.

This way you prevent the guide on the sheave from becoming damaged.

Keep the guy ropes slightly taut when you wind off the winches. This way you prevent slack rope from forming on the winch drum.

Risk of accidents from unintentional rotation of the rope drum Shut down the engine and secure it against unauthorized use before you start work on the winch drums. The rotating winch drum can inflict serious crushing injuries!

On the winch drum there are locking screws and fastening screws as follows: Fastening screws:

Hexagon bolt

Locking screw:

Hexagon socket bolt

The locking screws (1) are accessible from the outside at the winch drum.

The fastening screws (2) hold the clamp rail and must not be unfastened.

• Turn the winch drum until the locking screws are visible.

• Check the tightening torque of the 15 locking screws (1) (tightening torque = 270 Nm (221.2 lbf ft)).

In order to reach all 15 locking screws, the winch has to be turned further.

• Check the rope end fastening on the other winch drum in the same way.

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To reach the locking screw on the left-hand winch you must raise the MWL slightly.

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11 - 15

Maintenance 11.4 Maintenance work

11.4.7

M3

Lubricating the guy ropes

Grease, spare parts and tools

Designation

Quantity

GROVE part no.

1

03133770

Grease

– Brush, roller, spray gun, bath or pressure pump.

Lubricating the rope

Adhere to the instruction on lubricating the hoist ropes in the Maintenance Manual.

11.4.8

Lubricating other lubricating points

Grease, spare parts, tools

Lubricating grease Grease

M3

Designation to DIN 51502

Specification Classification

GROVE part no.

KP - L2K

DIN 51825

00554201

– Grease gun.

Prerequisites

– The MWL is rigged or has been set down or is in the transport position.

– The engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

Lubricating

D

Risk of crushing as a result of unintentional actuation.

Shut down the engine and secure it to prevent unauthorised use before lubricating. This way you prevent yourself from being injured by moving machine parts.

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G

• Make sure the aforementioned requirements have been met.

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

1 on the swivel ram 2 on the extension for the boom pivot pin 3 on the rear support

• Clean the lubricating nipples on the lubricating points (1) to (3).

• Lubricate until fresh grease is expelled from the lubricating point.

• Remove the excess grease.

• Lubricate the lubricating points on the other side of the MWL in the same

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way.

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11 - 17

Maintenance 11.4 Maintenance work

11.4.9 Grease, spare parts, tools

M3

Lubricating the winch gears

Lubricating grease Grease

Designation to DIN 51502

Specification Classification

GROVE part no.

KP - L2K

DIN 51825

00554201

– Grease gun.

Prerequisites

– The MWL has been set down or raised or switched off in transport position.

– If the MWL is set down, raise the MWL approximately 10°; ting down the MWL, p. 5 - 51.

Lubricating

à Raising/set-

• Make sure the aforementioned requirements have been met.

There are two lubricating nipples (1) on the winch axle.

• Clean the grease nipple (1).

• Lubricate the winch gear until fresh grease is expelled.

• Remove the excess grease.

• Lubricate the grease nipple on the other side of the winch gear.

• Lubricate the gears on the other winch in the

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same way.

11 - 18

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

11.4.10

M3

Lubricate gear rims

Spare parts and tools

Designation Adhesive lubricating grease (spray can)

H Prerequisites

Quantity

GROVE part no.

1

00554205

Observe the instructions and safety instructions on the adhesive lubricating grease packaging

– The MWL has been set down.

– The engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

Lubricating

G S

• Make sure the aforementioned requirements have been met.

Risk of crushing if the winches are operated inadvertently.

Shut down the engine and secure it against unauthorized use before you lubricate the gear rims. In this way you prevent being crushed by the rotating gear rim or flapping locking element.

Risk of damage and danger from slack rope Do not draw the deflection sheave too high when you wind the winches.

This way you prevent the guide on the sheave from becoming damaged.

Keep the guy ropes slightly taut when you wind off the winches. This way you prevent slack rope from forming on the winch drum.

The gear rims (2) are located on the right-hand side of both winches and can be accessed from below.

• Unlock the winch.

• Apply the lubricating grease: – around the entire circumference of the sprocket wheel (2) and – the gear teeth on the locking unit (1).

To do so, reel off the winch. In the process, hold the guy rope gently taut.

• Reel in the guy rope again.

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• Lock the winch.

• Lubricate the gear rim on the other winch in the same way.

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11 - 19

Maintenance 11.4 Maintenance work

11.4.11

M6

Checking the condition of the guy ropes

Spare parts and tools

Designation

Quantity

GROVE part no.

– Auxiliary crane authorised to lift persons or hoisting platform

H Prerequisites

If in doubt about damage assessment, always consult an official inspector.

– The MWL has been rigged.

– The truck crane is equipped for operation using the main boom with MWL. – The LMB is set.

– The main boom has been derricked to a working range equipped for telescoping.

Checking

• Make sure the aforementioned requirements have been met.

To check the guy ropes along their entire length, the main boom has to be extended with the MWL rigged.

G

Risk of accidents from rotating winches The rotating winches can inflict serious crushing injuries! Make sure that you do not come within range of the rotating winches.

• Bring the hoisting platform or another device authorised to lift persons near the winch (1).

• Slowly telescope out the main boom and, while doing so, check the guy rope along its entire length.

Information on the criteria for evaluating the condition of the rope or damage to the rope; Maintenance manual GMK 6400 – Hoist ropes – Assessing the condition of the hoist ropes.

à

• Check the guy rope on the other winch in the 2013.04.25

same way.

11 - 20

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

The following table indicates at what amount of wire breaks the rope must be changed.

H Supporting outer wires

The specifications in the table only apply to the original rope!

Regular lay rope (diameter 33 mm 33 mm (1.3 in))

141 - 160

G

on 6 x d (198 mm (7.8 in) length)

on 30 x d (990 mm (39.0 in) length)

6

13

Risk of accidents due to falling loads.

The guy rope must not be shortened. If the rope is shortened, there will no longer be the required number of safety turns on the winch drum when the main boom is fully extended. Without safety turns, the guy rope may slip out of the clamping device on the winch drum during operation.

Damage to the boom system and dropping of the load could result.

à Changing the guy ropes, p. 11 - 25.

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If the rope needs to be changed;

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11 - 21

Maintenance 11.4 Maintenance work

11.4.12 Grease, spare parts, tools

M 12

Lubricating the locking units

Lubricating grease Grease

Designation to DIN 51502

Specification Classification

GROVE part no.

KP - L2K

DIN 51825

00554201

– Grease gun.

Prerequisites

– The MWL has been rigged or set down.

– The engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

Lubricating

G

• Make sure the aforementioned requirements have been met.

Risk of crushing if the winches are operated inadvertently.

Shut down the engine and secure it against unauthorized use before you lubricate the locking unit. In this way you prevent being crushed by the rotating gear rim or flapping locking element.

The grease nipples (1) are located on the bearing points of the hydraulic cylinders of the locking units.

• Clean the grease nipple (1).

• Lubricate the locking unit until fresh grease is expelled.

• Remove the excess grease.

• Lubricate the locking unit on the other winch

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in the same way.

11 - 22

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

11.4.13

M 12

Changing the oil at the winch gears

Oil, spare parts, tools

Gear oil in litres (gal)

Designation to DIN 51502

Specification Classification

GROVE part no.

Approximately 1.0 (0.45)

C - LPF

MIL-L 2105 B API-GL-4/5 Viscosity: SAE 75 W-90 EP ISO - VG 220

02313611

Designation

Synthetic oil; do not mix this with mineral-based oils

Quantity

GROVE part no.

Gasket 10 x 14 x 1 DIN 7603

1

00117132

Plug

1

01069545

– Receptacle, approx. 2 l (0.53 gal).

Prerequisites

– The MWL is rigged or switched off.

– The engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

H Changing the oil

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S O H

The MWL must be level in the longitudinal direction, otherwise there is a false oil level.

• Make sure the aforementioned requirements have been met.

Risk of damage to the hoist gears The waste oil must be checked for abrasion particles. This test is used to detect any damage at an early stage; p. 11 - 24.

à

Risk of environmental damage due to leaking consumables Always let consumables drain into suitable receptacles. Wipe up any consumables that have leaked.

Store/dispose of consumables and any soaked equipment properly.

Ask about the applicable regulations.

When topping up, the oil is distributed slowly through the gear unit. The oil level therefore rises quickly in the standpipe at first, then drops slightly and then eventually rises again to its true level.

s MWL operating instructions GMK 6400

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11 - 23

Maintenance 11.4 Maintenance work

Draining oil

• Place a receptacle underneath the seal (3).

• Unfasten the bolt (1) and the plug (3) and allow the oil to drain.

• Screw the plug (3) back in. Replace it as necessary.

Topping up oil

• To speed up the filling process, remove the screw (4).

• Top up oil through the standpipe (1) up to the mark on the inspection glass (2).

• Screw the bolts (1) and (4) back in. Replace the gasket on the bolt (4).

• Change the oil on the other winch in the same way.

Checking the oil

G

Check the used oil for abrasion particles or have it tested at a laboratory; Maintenance Manual GMK 6400 Section Changing the oil/Checking the oil of the hoist gear.

à

When changing the oil for the first time, there may be abrasion particles in the oil. If you notice abrasion particles when changing the oil for the first time, first consult Manitowoc Crane Care before taking any further measures.

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H H

Danger of accidents due to the load falling If this test is not performed, there may be a risk of damage to the winch gear. This can cause the load to fall or the boom to be damaged.

11 - 24

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

11.4.14

Changing the guy ropes

H Information on changing ropes

Changing the guy ropes goes beyond the normal framework of maintenance work and should therefore only be carried out by personnel with special training. This section only describes the elements on the MWL which are needed loosening and fastening the guy ropes. This information assumes that you possess the specialist knowledge required for changing the wire cables properly without any detrimental effect to their service life.

If you have any doubts, contact Manitowoc Crane Care.

Errors made when installing new guy ropes reduce the service life considerably. Therefore: – Make sure that the guy ropes are not twisted when they are fitted.

– Avoid soiling and damage when fitting.

– Wind the guy ropes in the same direction in which the guy rope is reeled onto the reel.

– Tension the guy ropes slightly when reeling them up.

S

Risk of accidents from falling load Use only a replacement rope that has the same technical specifications as the defective rope, or an original replacement rope.

Spare parts and tools

– Torque wrench for torque of 270 Nm (221.2 lbf ft).

Prerequisites

– The MWL has been rigged and set down on the main boom.

– The MWL is connected electrically and hydraulically.

– The engine is not running and is secured against unauthorised use; Operating Instructions GMK 6400.

à

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s

MWL operating instructions GMK 6400

3 112 978 en

11 - 25

Maintenance 11.4 Maintenance work

Removing the guy rope

G

Risk of accidents due to rotating rope drum Turn off the engine and remove the ignition key so the winches cannot be operated without authorisation.

On the gantry mast

• Unwind the winch by about 0.5 m (2.0 ft).

• (A) – Remove the cotter pin (2) from the pin (1).

• Remove the distance ring (4) from the pin.

• Pull the pin (1) out of the hole.

• (B) – Remove the splice clamp (3) from the fork element (5).

• Unwind the guy rope from the winch drum until only the safety turns are still on the drum.

On the winch drum To reach the locking screws on the right-hand winch you have to raise the MWL slightly.

S

Risk of damage to components.

After unfastening the locking screws, only turn the winch in the wind winch on direction in order to access the locking screws.

This way you prevent the guy rope from being trapped between the winch drum and the winch frame and prevent components from becoming damaged.

On the winch drum there are locking screws and fastening screws as follows: Hexagon bolt

Locking screw:

Hexagon socket bolt

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Fastening screws:

11 - 26

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MWL operating instructions GMK 6400

Maintenance 11.4 Maintenance work

Only loosen the locking screws (1). Do not loosen the fixing bolts (2).

• Turn the winch drums until the locking screws (1) are visible.

• Perform the wind winch on movement in order to loosen the last locking screws (1).

• Completely unwind the guy rope and pull the guy rope (3) out from the clamping device.

• Remove the guy rope from the deflection sheave (1).

Attaching a new guy rope

On the winch drum

• Mark the new guy rope (1) for the required clamp length of 650 to 700 mm (25.6 to 27.6 in).

• Align the reel with the new guy rope in such a way that you can wind the guy rope onto the winch drum without kinks.

S

Risk of accidents from slipping rope clamp Always push the guy rope up to the designated clamp length in the clamping device.

In this way you prevent the guy rope from slipping out of the clamping device, the main boom becoming overloaded and the load falling.

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11 - 27

Maintenance 11.4 Maintenance work

S

Risk of damage to the guy rope After you have pushed the guy rope into the clamping device, you should only carry out the movement Wind winch in order to reach all the locking screws. In this way you prevent damage to the guy rope from its becoming clamped between the winch drum and the winch frame.

• Guide the marked end of the guy rope: – through the deflection sheave (1), – over the deflection sheave (2), – to the winch drum (3).

On the winch drum

• Push the guy rope (3) into the clamping device as far as the mark (and no further).

The rope end (2) must protrude slightly from the other side of the clamping device.

• Turn the winch drums in the wind winch up direction so that the locking screws (1) are visible.

• Tighten the locking screws (1) which you can reach with tightening torque of 270 Nm (221.2 lbf ft).

• Perform the wind winch on movement in order to tighten the last locking screws (1).

• Check the tightening torque on all locking screws. The guy rope will give slightly after the first tightening. tion on changing ropes;

11 - 28

3 112 978 en

à p. 11 - 25.

MWL operating instructions GMK 6400

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• Reel in the guy rope. Adhere to the informa-

Maintenance 11.4 Maintenance work

On the gantry mast

• Insert the splice clamp (3) into the holder (5) so that the bores align.

• Insert the pin (1) into the hole.

• Insert the distance ring (4) into the pin on both sides.

• Fasten the cotter pin (2) on the pin (1) on both sides.

• Wind up the guy rope so that the deflection sheave (1) is drawn into the guide (2).

• Stop the winch when the gap is A approxi-

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mately 150 mm (0.5 ft).

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11 - 29

Maintenance 11.4 Maintenance work

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11 - 30

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MWL operating instructions GMK 6400

Maintenance 11.5 Spare parts required for maintenance

11.5

Spare parts required for maintenance Adhere to the information on this subject in the Maintenance Manual; chapter Spare parts required for maintenance, sectionGeneral information.

à

You will find an overview of the lubricants required for maintenance of the maintenance in:

à à

p. 11 - 7, – Use of lubricant; Maintenance Manual.

– List of lubricants;

Assemblies and spare parts Superstructure

Quantity, in single parts For maintenance interval

GROVE part number W

M1

M3

M6

M 12

MWL 00117132

1

Plug

01069545

1

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11 - 31

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Gasket 10 x 14 x 1 DIN 7603

Maintenance 11.5 Spare parts required for maintenance

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11 - 32

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MWL operating instructions GMK 6400

12 Index

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12

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MWL operating instructions GMK 6400

Index

12

Index The index has the following structure: The names of the parts or components 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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12 - 1

Index

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12 - 2

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MWL operating instructions GMK 6400

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Index

A

Abbreviation abbreviation used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Addition to GMK 6400 operating manual Rigging modes for rigging at 0° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15 Addition to GMK 7450 operating manual to the driving state table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12 Uses that are only possible with the auxiliary hoist . . . . . . . . . . . . . . . . . . . . . 1 - 13

B

Boom extension Driving with rigged boom extension Axle loads at 12 m (39 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 28 at 18 m (59 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 at 24 m (79 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30 Bracing arms on the lattice extension folding in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15 folding out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14

C

CHECKLIST Bringing the boom system into operating condition – for the boom extension 7 - 7 Bringing the boom system into the rigging mode – for the boom extension . 7 - 8 Bringing the boom system into the rigging mode – for the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6 Putting the boom system into operating condition – for luffing jib . . . . . . . . . . 8 - 5 Putting the boom system into operating condition – for the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5 Putting the boom system into rigging mode – for luffing jib . . . . . . . . . . . . . . . 8 - 9 Rigging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Unrigging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7 Crane control display Submenu Operation – MWL Function of operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 Submenu Rigging – MWL Function of operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4

D

Deflection sheaves connecting to the head sheave axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 49 disconnecting from the head sheave axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 50 shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16 Driving with rigged boom extension and rigged MWL . . . . . . . . . . . . . . . . . . . . . 7 - 25 Driving with rigged heavy load lattice extension and rigged MWL . . . . . . . . . . . 9 - 21

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Index

12 - 4

E

Electrical connection Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 42 Establishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 42 Errors During operation with the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3 When operating with the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6

F

Finding information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11 Folding frame folding in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 34 folding out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 33 Function of the Mega Wing Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

H

Hand-held control Connection options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26 Overview of button combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 31 Heavy load lattice extension Driving with rigged heavy load lattice extension Axle loads at 4 m (13 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24 at 7.5 m (25 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 25 Turning loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15 Hydraulic connection Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 41

I

Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Installing and securing the rear pendant links A . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27 Installing the spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

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Driving with rigged lattice extension Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 26 Driving with rigged luffing jib and rigged MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25 Driving with rigged main boom Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29, 7 - 31, 8 - 35, 9 - 26 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29, 7 - 31, 8 - 35, 9 - 26 Rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 26 Driving with rigged main boom and rigged MWL . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25

2013.04.25

Index

L

Lattice extension operating manual Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Conversion table for USA imperial units of measure . . . . . . . . . . . . . . . . . . . . 1 - 16 Definition of positional references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 Finding information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Notes on ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Qualifications of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Safety instructions for working with the lattice extension . . . . . . . . . . . . . . . . . 2 - 4 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Lifting the MWL from the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 31 List of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7 Luffing jib Driving with a rigged luffing jib Axle loads at 25 m (82 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30 at 31 m (102 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31 at 37 m (121 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31 at 43 m (141 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32 at 49 m (161 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32 at 55 m (180 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33 at 61 m (200 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33 at 67 m (220 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34 at 73 m (240 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34

M

Main boom pivot pin Removing the extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25 Maintenance work on the Mega Wing Lift Cleaning Modules which require protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2 Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4 Maintenance work Guy ropes Checking the condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20 Checking the end fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 14 Checking the position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10 Lubricating the gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19 Winch gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 18 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 23 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13 Winches Lubricating the locking units . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16, 11 - 22 Spare parts requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 31 Use of lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7

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Index

O

12 - 6

Operating and display elements Function of the additional elements In the luffing jib submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9 In the main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9 In the RCL submenu "Enter rigging mode" . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25 In the submenu Operation – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9 In the submenu Rigging – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19 On the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26 Position of the additional elements On the crane control display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 On the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8 On the RCL display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 Operation with boom extension and MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Driving with a rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31, 8 - 35 Rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26 Further rigging work CHECKLIST – Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 CHECKLIST – Unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4 Extra information on positioning the hoist rope . . . . . . . . . . . . . . . . . . . . . . 7 - 5 Operation with braced boom system CHECKLIST – Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . . 7 - 7 CHECKLIST – Bringing into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9 Operation with MWL set down Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19 Putting into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Operation with heavy load lattice extension and MWL . . . . . . . . . . . . . . . . . . . . . . 9 - 1 Driving with a rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21 Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26 Rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22 Operation with braced boom system CHECKLIST – Putting into operating condition . . . . . . . . . . . . . . . . . . . . . . . 9 - 5 CHECKLIST – Putting into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7 Operation with MWL set down Operation with the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . 9 - 10 Putting into operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9 Putting into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 3 112 978 en

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Mega Wing Lift abbreviation used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 MWL raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 51 setting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 52 MWL on the main boom locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 46 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 47

2013.04.25

Index

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 Operation with luffing jib and MWL Driving with a rigged truck crane Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25 Rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 26 Further rigging work CHECKLIST – Unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4 Operation with braced boom system Bracing the boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18 CHECKLIST – Bringing into operating condition . . . . . . . . . . . . . . . . 8 - 5, 8 - 9 Derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15 Telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16 Operation with MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21 Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19 Putting into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21 Rigging mode – MWL is raised and not braced . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23 Operation with the main boom and the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1 Driving with a rigged truck crane Axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 28 Rigging modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 27 Operation with braced boom system Bracing the boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11 CHECKLIST – Putting into operating condition . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 CHECKLIST – Putting into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 Folding the gantry masts out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9 Locking/unlocking the winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14 Opening the submenu Operation – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7 Operation with MWL set down Main boom operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Operation with the MWL set down Derricking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19 Main boom operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19 Putting into operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17 Putting into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19 Operation with unbraced boom system and raised MWL Bringing into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23 Derricking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22 Main boom operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22 Putting into operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

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Positional references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8

R

Raise MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 58 Rear pendant links Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36 Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 37 Removing rear pendant links A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 29 Removing the spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32 Rests for rear pendant links Installing the rests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11 Removing the rests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16 Rigging the Mega Wing Lift Bracing arms on the lattice extension folding out/folding in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14 CHECKLIST Rigging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Unrigging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7 Connecting/disconnecting the rear pendant links . . . . . . . . . . . . . . . . . . . . . . . 5 - 36 Deflection sheaves shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16 Deflection sheaves on the head sheave axle connecting/detaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 49 Electrical connection establishing/disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 42 Folding in the gantry masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 64 Folding in/folding out the folding frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 33 Gantry masts folding in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 64 Greasing the peg on the holding frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 40 Hydraulic connection establishing/disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 41 Installing/removing the bracing arms on the lattice extension . . . . . . . . . . . . 7 - 11 Installing/removing the rear pendant links A . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27 Installing/removing the rests for the rear pendant links . . . . . . . . . . . . . . . . . . 5 - 11 Installing/removing the spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32 Locking / unlocking the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 54, 5 - 61 Locking/unlocking the MWL to/from the main boom . . . . . . . . . . . . . . . . . . . . 5 - 46 Locking/unlocking the winch – with the hand-held control . . . . . . . . . . . . . . . 5 - 54 Locking/unlocking the winches – from the crane cab . . . . . . . . . . . . . . . . . . . . 5 - 61 Main boom in the holding frame setting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 45 Menus Switching to another menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 57 Pushing in/pulling out the supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35 Raising / setting down the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 51, 5 - 58 Raising/setting down the MWL – with the hand-held control . . . . . . . . . . . . . 5 - 51 Setting the MWL down on the carrier/raising the MWL . . . . . . . . . . . . . . . . . . 5 - 30 Turnbuckle – positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39 Winding/unwinding – with the hand-held control . . . . . . . . . . . . . . . . . . . . . . . 5 - 55 Winding/unwinding the winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 55, 5 - 63

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Index

Index

Winding/unwinding the winches – from the crane cab . . . . . . . . . . . . . . . . . . 5 - 63

Safety instructions for working with lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4 Setting down the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 59 Setting the MWL down on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 30 Spare parts requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 31 Supports pushing in/pulling out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35 Symbols used ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8

T

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Transportation of the Mega Wing Lift Transport dimensions and weights add-on parts – lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 add-on parts – truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Mega Wing Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 Turnbuckle Operation positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 40 Transportation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39 Turning loads with the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15

U

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7

W

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Winches locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 61 locking/unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 54 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 62 winding/unwinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 55

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