Grove GMK4075 Operating Instructions Lattice Extension Manual – PDF DOWNLOAD

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Operating instructions lattice extension

Vehicle serial number:

2 084 629 en 16.02.2001

Important note

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

© Copyright reserved by Deutsche GROVE GmbH The passing on or duplication of this document as well as the use and disclosure of its contents are prohibited unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration of patent or utility model are reserved.

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Operating instructions lattice extension GMK 4075

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

These operating instructions consist of the following chapters:

1 Important information 2 Transport dimensions and weights 3 Two-stage swing-away lattice extension (additional equipment) 4 Boom extension (additional equipment) 5 Auxiliary single-sheave boom top (additional equipment)

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6 Index

Operating instructions lattice extension GMK 4075 2 084 629 en

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Wartungsanleitung GMK 4075

1 1

Important information

........................................ 1-

1

1.1

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

1

1.2

Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

2

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

2

1.3

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

3

1.4

Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

5

1.5

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

7

1.6

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

8

1.7

Specifications in US units of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10

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1.2.1

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Operating instructions lattice extension GMK 4075

Important information 1.1 About these operating instructions

1

Important information

1.1

About these operating instructions

H Validity of these operating instructions

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

This operating manual only applies to lattice extensions which were delivered by Deutsche GROVE GmbH. In addition, for the operation of the truck crane with a lattice extension described in these operating instructions, all details in the included operating instructions GMK 4075 for which the lattice extension was delivered from the factory, are applicable.

Prerequisites for assembly and operation

The lattice extensions described in these operating instructions may only be operated together with a GROVE truck crane GMK 4075 whose serial number is identical with the serial number that is marked on the lattice extensions.

Safety notes

For the operation of GMK 4075 with one of the lattice extensions described in these operating instructions is subject to: – all the basic safety instructions to be found in the subsequent section Basic safety instructions and – all the safety instructions contained in the supplied operating instructions of GMK 4075.

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Reference to other operating instructions

Cross references to other operating or maintenance instructions are stated as follows:

à Operating instructions GMK 4075, Part 2 Superstructure – Rigging work.

The number for the chapter on rigging work is found in front on the second page of the operating instructions indicated.

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1-1

Important information 1.2 Basic safety instructions

1.2

Basic safety instructions

1.2.1

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

H s

1-2

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

This symbol alerts you to situations where there is a danger of receiving an electric shock.

This symbol reminds you that you are working with substances which pose a risk to the environment. Take particular care. Further information on handling substances that pose a risk to the environment; Maintenance manual, Chapter Safety and environmental protection.

à

The vertical line to the left of the warning text indicates: this text, regardless of its length, relates to the warning symbol.

The hand with the pointing finger indicates passages that contain additional instructions and tips with regard to truck crane operation.

This symbol indicates that the topic is continued on the next page. Turn to the next page.

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G S B O

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

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Operating instructions lattice extension GMK 4075

Important information 1.3 Proper use

1.3

Proper use The truck crane GMK 4075 is constructed in accordance with the state of the art and the recognized safety regulations. Nevertheless, personal injury to the operator or a third party as well as damage to the crane and other property may occur during use.

The truck crane may only be modified with the consent of the manufacturer.

The truck crane GMK 4075 must only be used in proper working condition and for its intended purpose, while taking into account safe operation and any possible hazards.

Malfunctions that may affect the safe operation of the unit are to be corrected immediately.

The GMK 4075 truck crane may only be operated at temperatures of between –25 and +40 °C if it is not equipped with the relevant special equipment.

The GMK 4075 truck crane is intended solely for vertically lifting loads whose weight and centre of distribution are known, with a hook block reeved on the hoist rope and only in the permitted rigging modes. Any other use of the crane is not considered to represent proper usage.

The manufacturer is not liable for damage resulting from the improper or unauthorized use of the truck crane GMK 4075. The user shall take on full responsibility for any such use.

Proper use also entails – observing all crane documentation consisting of the operating instructions, the lifting capacity table, the outrigger pressure table and the safety manual

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– following the inspection and maintenance requirements specified in the maintenance manual.

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1-3

Important information 1.3 Proper use

Improper use includes – transporting loads on the carrier – pushing, pulling or lifting loads with the level adjustment system, the beams or the outrigger cylinders – pushing, pulling or lifting loads off the ground using the slewing gear, the derricking gear or the telescoping gear – pulling off fixed objects using the crane – two-hook operation with the boom extension and two-hook operation on the main boom head without additional equipment – operation when crane is not on outriggers (free on wheels) – defining SLI codes that do not correspond to the actual rigging mode – working with an overridden SLI or overridden lifting limit switch – after SLI deactivation, increasing the radius by pulling the raised load at an angle (e.g. with a chain hoist) – misuse of the outrigger pressure display as a safety function to prevent overturning after an SLI shutdown (outrigger pressure greater than 0 t) – road driving in an unauthorized driving mode (axle load, dimension) – moving the rigged crane in an unauthorized driving mode – the transportation of raised loads by moving the truck crane – use of equipment that is not authorized for use with the crane – transporting passengers on unauthorized parts of the vehicle – transporting passengers without previous written permission from the manufacturer – carrying passengers outside the driver's cab – loading and unloading work, i.e. continuous operation without a sufficiently long break

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

1-4

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Operating instructions lattice extension GMK 4075

Important information 1.4 Organizational measures

1.4

Organizational measures The operating instructions and the lifting capacity table should be kept in the truck crane for immediate access at all times, and must not be removed from the truck crane. You must have read and understood the operation and safety instructions in these operating instructions, and comply with them when working.

In addition to the operating instructions and the lifting capacitytable, observe all general, statutory and otherwise applicable regulations concerning accident prevention and environmental protection. You must have read and understood these and work accordingly.

This could include: – the use of hazardous materials, – wearing personal protective equipment, – traffic regulations or – all applicable regulations concerning the operation of a crane.

Ensure that those appointed to work on the truck crane are given the information required to carry out the work before starting operations. Give your employees (e.g. banksmen, slingers, rigging personnel) appropriate instructions.

Ensure that the maintenance personnel possess the necessary know-how to safely operate the crane. Ensure that the maintenance personnel have access to the operating instructions.

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

Responsibilities related to crane operation, rigging, maintenance and repair work must be clearly defined.

Ensure that only the appointed employees operate the truck crane.

Do not leave long hair down or wear loose clothing or jewellery (including rings) when working with the crane. These could get caught or pulled into the unit and result in injury.

Use your personal protective equipment whenever necessary or prescribed.

Observe all safety and warning signs on the truck crane.

Ensure that all sfety and warning signs on the truck crane remain legible.

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s

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1-5

Important information 1.4 Organizational measures

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

Familiarize yourself with the location and operation of the fire extinguishers on every site.

Note the fire alarm and fire fighting facilities on the site.

Should the operating behaviour of the truck crane change in such a manner that the safety conditions are affected, e.g. if you doubt the truck crane´s operating safety, stop the machine immediately and inform the appropriate responsible persons.

Do not make any changes to the programmable controlsystems (e.g. the SLI).

Do not modify or mount attachments to the truck crane without the consent of the manufacturer, if such changes could affect the safety of the unit. This also applies to – the installation of safety devices, – the adjustment of safety devices and valves.

Welding work on load-bearing parts may only be carried out by properly qualified personnel with the manufacturer's permission. To avoid any damage, especially to electronic parts, there are certain steps you must take before doing any welding work. You should thus always consult GROVE Customer Support before doing any welding work.

Ensure that both the prescribed periods and the periods specified in the operating and maintenance instructions for regular testing, inspection and maintenance work are maintained.

Replace the hydraulic hose lines, or have them replaced, at the prescribed intervals, even if no safety defects are noticeable.

Replacement parts must fulfill the technical requirements prescribed by the manufacturer. Genuine spare parts always meet these requirements.

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It is imperative that appropriate service equipment be used when carrying out repair work.

1-6

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Operating instructions lattice extension GMK 4075

Important information 1.5 Personnel qualifications

1.5

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

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

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

Only reliable personnel may operate the truck crane.

As a truck crane operator you are obliged to fulfill a number of requirements: – You must possess a driving licence for this type of vehicle that is valid in the country in which you are working.

– You must have general knowledge of crane operation and any qualifications that may be required by the country in which you are working.

– You must be familiar with and have understood the operating instructions.

– You must be familiar with and have understood the accident prevention regulations.

– You must fulfil all physical and mental requirements for truck crane operation, e.g. perfect sight and hearing and the ability to react quickly.

Please refer to the section in the Safety manual titled You as crane driver and operator.

Only experienced personnel familiar with the applicable accident prevention regulations are authorized to sling loads and train crane operators.

Your responsibilities as a crane operator (including those concerning traffic regulations) must be clearly defined. You must be in a position to refuse to carry out any instructions given to you by a third party that violate safety regulations.

Only trained, experienced personnel with special knowledge in the fields of hydraulics, pneumatics and electrical equipment may carry out maintenance work on the truck crane.

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Deutsche GROVE GmbH gives general and type-related crane operator and technical courses.

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1-7

Important information 1.6 Safety instructions for truck crane work

1.6

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

Check over the truck crane before beginning crane work. Check the condition of the truck crane carefully using the check lists in the operating instructions. Do not assume that everything is in working order simply because it was in working order when work was last completed.

Check daily before starting to work with the crane that all guards and safety devices are correctly fitted and that they are all in a proper condition.

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

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. During rigging and maintenance work on machine sections above body height which have no apparatus for accessing, always use the extension ladder supplied (e.g. when reeving the hoist rope on the boom head).

Keep all handles, steps, step treads and ladders free of dirt, snow and ice.

Check all operating and control elements in the crane operator's cab before starting the crane engine.

Monitor all warning and indicator lamps as well as the control instruments when the engine is started.

Make sure that there are no unauthorised people in the vicinity of or on the truck crane when rigging or during crane work. Secure the danger zone using cordons and mark them as such.

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

1-8

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Operating instructions lattice extension GMK 4075

Important information 1.6 Safety instructions for truck crane work

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

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

Only use equipment (counterweight sections, lattice extensions) that belongs to your truck crane. The serial number of both the truck crane and the equipment must be identical.

Simultaneously lifting loads with two cranes is particularly dangerous. Use extreme caution when carrying out this type of work.

When work is interrupted, always put the load down and never leave the truck crane if a load is raised.

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

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Crane work carried out in the vicinity of supply lines such as oil, gas or other supply lines is dangerous and requires that special precautionary measures be taken. Please refer to the section titled Crane operation under special operating conditions in the Safety manual, and observe the relevant national regulations.

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1-9

Important information 1.7 Specifications in US units of measurement

1.7

Specifications in US units of measurement These operating instructions use mainly metric units of measurement.

Should you be working in a country that uses US units of measurement, refer to the following table for a comparison of the units.

– The first column shows the metric units of measurement.

– The second column shows the converted units of measurement, which are also used in the lifting capacity tables.

– The third column shows the rounded values which are used for better legibility if both units of measurement are stated (in Chapter 2, Transport dimensions and weights and in the diagrams showing the composition of the individual lattice extensions).

Prescribed length in metric measuring units

Corresponding length in US measuring units According to the lifting capacity table

Rounded length in US measuring units in these operating instructions

32.8 ft

33 ft

17 m Two-stage swing-away lattice extension

55.8 ft

56 ft

22 m Boom extension

72.2 ft

72 ft

27 m Boom extension

88.6 ft

89 ft

7 m section

23.0 ft

23 ft

5 m section

16.4 ft

16 ft

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10 m Swing-away lattice extension

1 - 10

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Operating instructions lattice extension GMK 4075

2 2

Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . .

2-

1

2.1

In metric units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1

Two-stage swing-away lattice extension and boom extension . . . . . . . . . . . . . 2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1 1

In US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

3

Two-stage swing-away lattice extension and boom extension . . . . . . . . . . . . . 2 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

3 3

2.1.1 2.1.2 2.2

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2.2.1 2.2.2

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Operating instructions lattice extension GMK 4075

Transport dimensions and weights 2.1 In metric units

2 2.1

Transport dimensions and weights

In metric units This section contains the transport dimensions and weights of the lattice extensions in metric units.

2.1.1

Description

Length x width x height (m)

Weight (kg)

Two-stage swing-away lattice extension (complete, folded together)

10.50 x 0.90 x 1.20

1350

10 m section

10.50 x 0.90 x 1.20

1 060

7 m section

7.00 x 0.50 x 0.60

300

5 m section with deflection sheave

5.20 x 0.90 x 1.20

460

5 m section without deflection sheave

5.20 x 0.90 x 1.20

350

Auxiliary single-sheave boom top

Description

Length x width x height (m)

Weight (kg)

Auxiliary single-sheave boom top complete with pins

1.00 x 0.40 x 1.00

60

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2.1.2

Two-stage swing-away lattice extension and boom extension

Operating instructions lattice extension GMK 4075 2 084 629 en

2-1

Transport dimensions and weights 2.1 In metric units

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Blank page

2-2

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Operating instructions lattice extension GMK 4075

Transport dimensions and weights 2.2 In US units

2.2

In US units This section contains the transport dimensions and weights of the lattice extensions in US units.

2.2.1

Two-stage swing-away lattice extension and boom extension

Description

2.2.2

Length x Width x Height (ft)

Weight (lbs)

Two-stage swing-away lattice extension (complete, folded together)

35.0 x 3.0 x 4.0

2980

10 m section

35.0 x 3.0 x 4.0

2340

7 m section

23.0 x 1.7 x 2.0

670

5 m section with deflection sheave

17.2 x 3.0 x 4.0

1020

5 m section without deflection sheave

17.2 x 3.0 x 4.0

780

Auxiliary single-sheave boom top

Description

Weight (lbs)

3.3 x 1.4 x 3.3

140

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Auxiliary single-sheave boom top complete with pins

Length x Width x Height (ft)

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2-3

Transport dimensions and weights 2.2 In US units

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Blank page

2-4

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Operating instructions lattice extension GMK 4075

3 3

3-

1

Additional operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

1

In the crane cabin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operating and display instruments on the lattice extension . . . . . . . . . . . . . . . 3 -

2 4

3.2

Identification of the two-stage swing-away lattice extension . . . . . . . . . . . . . . . 3 -

5

3.3

Assembly of the lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

7

3.4

Centres of gravity for slinging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

8

3.5

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

9

3.1 3.1.1 3.1.2

3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.6.7 3.6.8 3.6.9 3.6.10 3.6.11 3.6.12 3.6.13 3.6.14 3.6.15 3.6.16 3.6.17

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Two-stage swing-away lattice extension (additional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of the required rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK LIST: Installing the (two-stage) swing-away lattice extension . . . . . . .

CHECK LIST: Uninstalling (two-stage) swing-away lattice extension . . . . . . . .

CHECK LIST: Rigging the 10 m swing-away lattice extension . . . . . . . . . . . . . .

CHECK LIST: Unrigging the 10 m swing-away lattice extension . . . . . . . . . . . .

CHECK LIST: Rigging the 17 m two-stage swing-away lattice extension . . . . .

CHECK LIST: Unrigging the 17 m two-stage swing-away lattice extension . . .

3333333-

9 10 12 14 18 23 27

Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33 Preparing the truck crane for rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose drum for hydraulic supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Folding the run-up rail out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections with folded lattice extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pin connections on the main boom head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pin connections on the latticeextension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swinging the lattice extension onto the main boom head . . . . . . . . . . . . . . .

Swivelling the lattice extension when rigging . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical connections on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . .

Establishing/disconnecting the hydraulic connection . . . . . . . . . . . . . . . . . . . .

Folding out / in the deflection sheaves on the 10 m section . . . . . . . . . . . . . . .

Positioning/removing the hoist cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting limit switch on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anemometer on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transportation on a separate vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33333333333333333-

33 35 38 41 42 49 53 55 56 58 60 61 64 66 68 69 70

3.7

Raising and setting down the main boom with rigged lattice extension . . . . . . 3 - 71

3.8

Telescoping with rigged lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 73

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3.9

Operation with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 75

3.9.1 3.9.2

SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 75 Procedure if the permissible wind speed is exceeded . . . . . . . . . . . . . . . . . . . . 3 - 76

3.10

Turning loads with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77

3.10.1 3.10.2 3.11 3.11.1 3.11.2 3.11.3

Prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77 Setting SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 78 Driving with rigged crane and installed lattice extension. . . . . . . . . . . . . . . . . . . 3 - 83 Driving route. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 83 Boom positions and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 84 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 86

3.12

Malfunction when working with lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 3 - 91

3.13

Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 93 Modules in need of protection during cleaning work. . . . . . . . . . . . . . . . . . . . . 3 - 93 Maintenance work M1, monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 94

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3.13.1 3.13.2

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.1 Additional operating and display elements

3

Two-stage swing-away lattice extension (additional equipment)

3.1

Additional operating and display elements When the GMK 4075 is equipped with lattice extension, certain operating and display elements in the crane cab also apply to the operation of the lattice extension. The following sections describe: – all operating and display elements in the crane cabine required for the operation of the lattice extension.

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– the operating elements located directly on the lattice extension.

Operating instructions lattice extension GMK 4075 2 084 629 en

3-1

Two-stage swing-away lattice extension (additional equipment) 3.1 Additional operating and display elements

3.1.1

In the crane cabin In the crane cabin there are additional operating and display elements on the right control console on the display crane control and on the plug-in module of the safe load indicator.

At the control console right

At the right control console there is an additional rocker switch and the right control lever has an additional function.

The rocker switch lower lattice extension on / off (1) is used for switching on and off the derricking gear at the lattice extension.

There is an indicator lamp in the rocker switch. The indicator lamp shows, whether the derricking gear is switched on or off.

Indicator lamp is dimly illuminated:

Derricking gear is switched off

Indicator lamp is brightly illuminated:

Derricking gear is switched on

After switching on the ignition that condition is reproduced, which was saved after the last switch-off.

Switching on the derricking gear: Indicator lamp is slightly illuminated.

Press rocker switch upwards once; the indicator lamp will then be brightly illuminated.

If the control lever is assigned more than one function, all other driving gears which are assigned the same movement of the control lever are switched off. Indicator lamps in the corresponding rocker switches are dimly illuminated.

Switching off the derricking gear: Indicator lamp is brightly illuminated Press rocker switch upwards once; the indicator lamp will then be dimly illuminated.

If the control lever is assigned more than one function, the derricking gear can also be switched off by switching on a driving gear which is assigned the same movement of the control lever.

If the derricking gear of the lattice boom is switched on, the lattice boom is lowered with the right control lever.

3-2

M ove the control lever to the left

Lower the lattice extension

Control lever to the right, control lever to the left

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Raise the lattice extension

Two-stage swing-away lattice extension (additional equipment) 3.1 Additional operating and display elements

On the crane control display

In case of an electrically connected lattice extension there are various display and setting possibilities on the crane control display. For calling up menus and for setting GMK 4075 Operating instructions, Part 2 Superstructure.

à

Indicator lamp lower lattice extension on / off (1) is displayed in the main menu. The indicator lamp shows, whether the derricking gear of the lattice extension is switched on or off.

Glows green:

Derricking gear of the lattice extension is switched on

Glows red:

Derricking gear of the lattice extension is switched off

In the sub-menu driving gear speed, the symbol (1) for the lattice extension operation is shown in yellow and additionally the maximum speed for lowering the lattice extension can be entered for other driving gears.

In the sub-menu operating hours counter, the value in the display under the symbol for the lattice extension (1) increases to the extent of time, in which the lattice extension is derricked.

At the safe load indicator

Status display for length of lattice extension with a membrane switch Displays the length of the lattice extension in metres. The status display is activated when an SLI code for working with the lattice extension is entered in the rigging mode status display. The displayed length is obtained from the entered SLI code. If the entry mode is activated in the rigging mode display, pressing the membrane button repeatedly displays other values which are permitted according to the lifting capacity table in ascending order.

When the greatest length is reached and the membrane button is pressed again, the display starts again at the beginning with the lowest value.

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1/0

The following displays and membrane switches are active on the safe load indicator with electrically connected lattice extension.

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Two-stage swing-away lattice extension (additional equipment) 3.1 Additional operating and display elements

1%0

K 3.1.2 Switch units

Status display for angle of lattice extension with membrane switch Displays the current measured angle of lattice extension to the main boom in degrees. The status display is activated when an SLI code for working with the lattice extension is entered in the rigging mode status display. No values can be selected on the display.

Membrane button with indicator lamp for angle of lattice extension After pressing the switch, the green indicator lamp in the button lights up and the current angle of the lattice extension, in relation to the horizontal is shown in the information status display.

Operating and display instruments on the lattice extension There are two switch units each with two push buttons on the lattice extension.

The push buttons (1) and (2) have the same function on both the switch units.

1 Raise lattice extension push-button 2 Lower lattice extension push-button

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

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Two-stage swing-away lattice extension (additional equipment) 3.2 Identification of the two-stage swing-away lattice extension

3.2

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

The following sections are identified by the serial number: – the 10 m section on the fixed section, – the 10 m section on the inclinable section,

S H

Only operate the truck crane with sections of the two-stage swing-away lattice extension that have the same serial number as the crane.

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

This prevents malfunctions and damage.

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

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

The two-stage swing-away lattice extension should only be adjusted by local GROVE Customer Support.

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S

– the 7 m section.

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Two-stage swing-away lattice extension (additional equipment) 3.2 Identification of the two-stage swing-away lattice extension

Serial numbers on 10 m section

The 10 m section consists of a fixed section and an inclinable section.

On the inclinable section the serial number (1) is at the front on a sheet to the right of the deflection sheave.

On the fixed section the serial number (2) is at the rear on a sheet in the upper boom.

Serial number on 7 m section

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On the 7 m section the serial number (1) is at the rear on a sheet in the upper boom.

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Two-stage swing-away lattice extension (additional equipment) 3.3 Assembly of the lattice extensions

3.3

Assembly of the lattice extensions

10 m swing-away lattice extension (33 ft swing-away lattice extension)

10 m section (33 ft section)

17 m swing-away lattice extension (56 ft swing-away lattice extension)

10 m section (33 ft section)

H

7 m section (23 ft section)

The lengths of 10 m and 17 m respectively equal the distance between the centre of the locking pin (on the main boom head) and the front edge of the head sheave.

The designations 10 m section and 7 m section have been adapted to these lengths. The total length of the individual sections is greater or smaller; Transport dimensions and weights, p. 2 - 1.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.4 Centres of gravity for slinging

3.4

Centres of gravity for slinging Observe the centres of gravity of the lattice extension and the swing-away lattice extension when you sling the lattice extension to an auxiliary crane for removal or installation.

G

Risk of accidents from falling two-stage swing-away lattice extension!

Always observe relevant centres of gravity shown in illustration below when slinging and use suitable slinging material with sufficient load bearTransport dimensions and weights, p. 2 - 1. ing capacity; In this way you prevent the lattice extension from slipping out, falling and causing injury during installation or removal.

à

The distances are always measured from the centre of the fork elements.

For the 17 m two-stage swing-away lattice extension, swung out, the distance for the centre of gravity is (1) = 5900 mm.

For the 17 m two-stage swing-away lattice extension, folded, the distance for the centre of gravity is (2) = 4600 mm.

For the 7 m two-stage swing-away lattice extension on its own, the distance for the centre of gravity is (4) = 3060 mm.

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For the 10 m two-stage swing-away lattice extension on its own, the distance for the centre of gravity is (3) = 3920 mm.

Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

3.5

Checklists for rigging work

3.5.1

Overview of the required rigging work There are different initial states for rigging the lattice extension, depending on whether – the lattice extension is folded at the side of the main boom or – The lattice extension has been dismantled for on-road driving, Driving mode tables Operating Instructions GMK 4075, Part 1 Carrier – Driving the truck crane.

à

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

Initial state

Corresponding rigging work CHECK LISTS:

The lattice extension is located at a side on the main boom before the crane operation

Rigging the 10 m swing-away lattice extension; à p. 3 - 10.

Unrigging the 17 m two-stage swing-away-lattice extension;

à p. 3 - 23.

The lattice extension was removed completely

CHECK LIST:

Installing two-stage swingaway lattice extension;

à p. 3 - 10.

CHECK LISTS:

after the crane operation

The lattice extension must be folded to the side of the main boom

Unrigging the 10 m swingaway lattice extension;

à p. 3 - 18.

Unrigging the 17 m two-stage swing-away lattice extension;

à p. 3 - 27.

CHECK LIST:

Removing the two-stage swingaway lattice extension;

à p. 3 - 12.

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The lattice extension is to be removed for on-road driving

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

3.5.2

CHECK LIST: Installing the (two-stage) swing-away lattice extension

H

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

Observe the warning and safety information given there.

Prerequisites: – The truck crane is on outriggers or the main boom is placed on the boom support.

– An auxiliary crane is available.

1. If necessary, connect the hose drum for hydraulic supply; Hose drum for hydraulic supply, p. 3 - 38.

à

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

à

3. Sling (two-stage) swing-away lattice extension on auxiliary crane; Centres of gravity for slinging, p. 3 - 8.

à

4. Lift (two-stage) swing-away lattice extension in front of the main boom with the auxiliary crane and lock the 10 m section to the right of the main boom head; Pin connections on the main boom head, p. 3 - 49.

5. Establish hydraulic connection between the lattice extension and the Establishing/disconnecting the hydraulic connection, main boom; p. 3 - 60.

à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

6. Establish electrical connection between the lattice extension and the main boom; Electrical connections on the lattice extension, p. 3 - 58.

à

7. Attach the guide rope to the head of the 10 m section.

H

If the lattice extension needs to be rigged in front of the main boom, proceed as from point 10.

8. If the lattice extension is to be folded up at the side of the main boom, fold out run-up rail; Folding the run-up rail out/in, p. 3 - 41.

à

9. The other types of rigging work for folding up the lattice extension at the side are described in the CHECK LIST: Unrigging the 10 m swing-away lattice extension from the point onwards 12. p. 3 - 19.

à

10. If the lattice extension needs to be rigged in front of the main boom, attach guide ropes to the head of the 10 m section.

The other types of rigging work for the 10 m swing-away lattice extension are described in the CHECK LIST: Rigging the 10 m swing-away lattice extension from the point onwards 14. p. 3 - 16.

The other types of rigging work for the 17 m two-stage swing-away lattice extension are described in the CHECK LIST: Rigging the 17 m swingaway lattice extension from the point onwards 13. p. 3 - 25.

à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

3.5.3

CHECK LIST: Uninstalling (two-stage) swing-away lattice extension

H

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

Observe the warning and safety information given there.

Prerequisites: – The truck crane is on outriggers or the main boom is placed on the boom support.

– An auxiliary crane is available.

1. Carry out all of the rigging work for a rigged 10 m swing-away lattice extension listed in the CHECK LIST: Unrigging 10 m swing-away lattice extension up to and including point 9.; p. 3 - 19.

à

2. Carry out all of the rigging work for a rigged 17 m two-stage swingaway lattice extension listed in the CHECKLIST: Unrigging 17 m swingaway lattice extension up to and including point 15. are listed; p. 3 - 29.

à

3. Disconnect hydraulic connection between the lattice extension and the main boom; Establishing/disconnecting the hydraulic connection, p. 3 - 60.

à

4. Disconnect electrical connection between the lattice extension and the Electrical connections on the lattice extension, p. 3 - 58. main boom;

5. Slinging (two-stage) swing-away lattice extension on auxiliary crane; Centres of gravity for slinging, p. 3 - 8.

à

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à

Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

6. Remove locking pins on both sides between 10 m section and main boom head and place (two-stage) swing-away lattice extension onto separate vehicle using auxiliary crane; Pin connections on the main boom head, p. 3 - 49, Transportation on a separate vehicle, p. 3 - 70.

à

à

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

à

8. If necessary, remove hose drum connection for hydraulic supply; Hose drum for hydraulic supply, p. 3 - 38.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

3.5.4

CHECK LIST: Rigging the 10 m swing-away lattice extension

H

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

Observe the warning and safety information given there.

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

à

2. If necessary, connect the hose drum for hydraulic supply; for hydraulic supply, p. 3 - 38.

à Hose drum

3. Check if the lattice extension was unrigged properly and is in transport condition; Transport condition with lattice extension folded at the side, p. 3 - 37.

à

4. Folding out the run-up rail;

H

à Folding the run-up rail out/in, p. 3 - 41.

If only the 10 m section is folded at the side of the main boom – proceed as from point 7.

5. Move the connection in the middle area on 10m section; Joint at the 10 m section, p. 3 - 46.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

6. Release connection at the pivot point between 10 m section and 7 m section; Pin connections on the latticeextension, p. 3 - 53.

à

7. If only the 10 m section is folded at the side of the main boom, remove connection between 10 m section and main boom (rear); Connection between 10 m section and main boom, p. 3 - 48.

à

8. Establish electrical connection between the lattice extension and the main boom; 10 m swing-away lattice extension, p. 3 - 58.

à

9. Establish hydraulic connection between the lattice extension and the main boom; Establishing/disconnecting the hydraulic connection, p. 3 - 60.

à

10. Swing 10 m section onto the main boom head; extension onto the main boom head, p. 3 - 55.

à Swinging the lattice

11. Fasten 10 m section onto the main boom head with pins on right-hand side; Pin connections on the main boom head, p. 3 - 49.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

12. Secure the lattice extension on the main boom with guide rope; Securing lattice extension with cord, p. 3 - 34.

à

13. Release the connection in the front area, for this, if necessary, press down the slewing axle mechanically; Removing the connection, p. 3 - 44.

à

14. Swing the 10 m section in front of the main boom head; the lattice extension when rigging, p. 3 - 56.

à Swivelling

15. Pin the 10 m section onto the main boom head, on left-hand side; Pin connections on the main boom head, p. 3 - 49.

à

16. Fold out both deflection sheaves on the 10 m section; in the deflection sheaves on the 10 m section, p. 3 - 61.

à Folding out /

17. Place the hoist cable over both deflection sheaves and head sheave of the 10 m section; Positioning/removing the hoist cable, p. 3 - 64.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

18. Move the anemometer from the head of the main boom to the head of the 10 m section; Anemometer on the lattice extension, p. 3 - 68.

à

19. Move the lifting limit switch from the head of the main boom to the head of the 11 m section; Lifting limit switch on the lattice extension, p. 3 - 66.

à

20. Reeve the hoist cable on the hook block; the lattice extension, p. 3 - 65.

à Possible reeving methods on

21. Attach the lifting limit switch weight and guide hoist rope through the weight; Operating instructions GMK 4075, Part 2 Superstructure – Rig-

à

ging work.

00==

22. SLI code according to the Enter the lifting capacity table for the actual rigging mode of the truck crane with the 10 m swing-away lattice extension, setting the rigging mode Operating instructions GMK 4075, Part 2

à

Superstructure – Crane operation.

à p. 3 - 71. à p. 3 - 73.

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

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

3.5.5

CHECK LIST: Unrigging the 10 m swing-away lattice extension

H

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

Observe the warning and safety information given there.

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

à Preparing the truck crane for rig-

2. Retract the main boom completely and lower it into the horizontal position.

00==

3. Enter SLI code according to lifting capacity table for the actual rigging mode of the truck crane with the 10 m swing-away lattice extension,

setting the rigging mode à Operating instructions GMK 4075, Part 2 Superstructure – Crane operation.

4. Remove the lifting limit switch weight and move lifting limit switch from the head of the 10 m section to the head of the main boom; Lifting limit switch on the lattice extension, p. 3 - 66.

à

5. Unreeve the hoist cable from the hook block and remove it from the lattice extension; Possible reeving methods on the lattice extension, p. 3 - 65.

à

à Anemometer on the lattice extension, p. 3 - 68.

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6. Remove anemometer;

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

7. Fold in both deflection sheaves on the 10 m section; the deflection sheaves on the 10 m section, p. 3 - 61.

à Folding out / in

8. Reel hoist cable up to the main boom head.

9. Attach the guide rope to the head of the 10 m section.

10. Remove left-hand locking pin between the 10 m section and the main boom head; Pin connections on the main boom head, p. 3 - 49.

à

11. Raise the main boom completely; p. 3 - 69.

à Derricking the lattice extension,

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12. Swing the 10 m section onto the main boom; tension when rigging, p. 3 - 56.

à Swivelling the lattice ex-

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

13. Lower the lattice extension so that it is positioned on the run-up rail.

14. Establish the connection in the front area; p. 3 - 45.

à Establishing a connection,

15. Remove right hand locking pin between the 10 m section and the main boom head; Pin connections on the main boom head, p. 3 - 49.

à

16. Swing the 10 m section on the run-up rail onto the main boom; Swivelling the lattice extension when rigging, p. 3 - 56.

à

17. Secure the connection in the front area; p. 3 - 43.

If the 7 m section is not attached to the main boom – proceed as from Point 20.

18. Move the connection in the middle area 7 m section / 10 m section; 7 m section / 10 m section joint, p. 3 - 45.

à

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à Securing the connection,

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

19. Establish the connection at the pivot point between 10 m section and 7 m section; Pin connections on the latticeextension, p. 3 - 53.

à

H

If the 7 m section is attached to the main boom – proceed as from point 21.

20. Establish the connection between 10 m section and the main boom in the rear area; Connection between 10 m section and main boom, p. 3 - 48.

à

21. Remove electrical connection between the lattice extension and the main boom; 10 m swing-away lattice extension, p. 3 - 58.

à

22. Disconnect hydraulic connection between the lattice extension and the main boom; Establishing/disconnecting the hydraulic connection, p. 3 - 60.

à

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

à

à Folding the run-up rail out/in, p. 3 - 41.

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24. Folding in the run-up rail;

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

25. If necessary, remove hose drum connection for hydraulic supply; Hose drum for hydraulic supply, p. 3 - 38.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

3.5.6

CHECK LIST: Rigging the 17 m two-stage swing-away lattice extension

H

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

Observe the warning and safety information given there.

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

à

2. If necessary, connect the hose drum for hydraulic supply; for hydraulic supply, p. 3 - 38.

à Hose drum

3. Check if the lattice extension was unrigged properly and is in transport condition; Transport condition with lattice extension folded at the side, p. 3 - 37.

à

4. Folding out the run-up rail;

à Folding the run-up rail out/in, p. 3 - 41.

5. Move the connection in the middle area 7 m section / 10 m section; 7 m section / 10 m section joint, p. 3 - 45.

à

6. Remove the connection between 7 m section and the main boom in the rear area; Connections in the rear area, p. 3 - 47.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

7. Establish electrical connection between the lattice extension and the main boom; 10 m swing-away lattice extension, p. 3 - 58.

à

8. Establish hydraulic connection between the lattice extension and the main boom; Establishing/disconnecting the hydraulic connection, p. 3 - 60.

à

9. Swinging the lattice extension onto the main boom head; the lattice extension onto the main boom head, p. 3 - 55.

à Swinging

10. Fasten 10 m section onto the main boom head with pins on right-hand side; Pin connections on the main boom head, p. 3 - 49.

à

11. Secure the lattice extension on the main boom with guide rope; Securing lattice extension with cord, p. 3 - 34.

à

12. Remove the connection in the front area, for that, if necessary, press down the slewing axle mechanically; Removing the connection, p. 3 - 44.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

13. Swing the lattice extension in front of the main boom head; Swivelling the lattice extension when rigging, p. 3 - 56.

à

14. Pin the 10 m section onto the main boom head, on left-hand side; Pin connections on the main boom head, p. 3 - 49.

à

15. Attach the guide rope to the head of the 7 m section.

16. Move the connection in the middle area on 10 m section; Joint at the 10 m section, p. 3 - 46.

à

17. Swinging the 7 m section in front of the 10 m section; Swing the 7 m section in front of the 10 m section, p. 3 - 57.

à

18. Fasten the 7 m section on left-hand side in front of 10 m section with a pin; Pin connections on the latticeextension, p. 3 - 53.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

19. Establish electrical connection between the 10 m and 7 m sections; 17 m two-stage swing-away lattice extension, p. 3 - 59.

à

20. Fold out both deflection sheaves on the 10 m section; in the deflection sheaves on the 10 m section, p. 3 - 61.

à Folding out /

21. Place the hoist cable over both deflection sheaves and head sheave of the 7 m section; Positioning/removing the hoist cable, p. 3 - 64.

à

22. Move the anemometer from the head of the main boom to the head of the 10 m section; Anemometer on the lattice extension, p. 3 - 68.

à

23. Move the lifting limit switch from the head of the main boom to the head of the 11 m section; Lifting limit switch on the lattice extension, p. 3 - 66.

à

à Possible reeving methods on

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24. Reeve the hoist cable on the hook block; the lattice extension, p. 3 - 65.

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

25. Attach the lifting limit switch weight and guide hoist rope through the weight; Operating instructions GMK 4075, Part 2 Superstructure – Rig-

à

ging work.

00==

26. SLI code according to the enter the lifting capacity table for the actual rigging mode of the truck crane with the 17 m swing-away lattice extension, setting the rigging mode Operating instructions GMK 4075, Part 2

à

Superstructure – Crane operation.

H 3.5.7

à p. 3 - 71. à p. 3 - 73.

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

CHECK LIST: Unrigging the 17 m two-stage swing-away lattice extension

H

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

Observe the warning and safety information given there.

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

à Preparing the truck crane for rig-

2. Retract the main boom completely and lower it into the horizontal position.

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00==

3. Enter SLI code according to lifting capacity table for the actual rigging mode of the truck crane with the 17 m swing-away lattice extension, set-

ting the rigging mode à Operating instructions GMK 4075, Part 2 Superstructure – Crane operation.

4. Remove the lifting limit switch weight and move lifting limit switch from the head of the 7 m section to the head of the main boom; Lifting limit switch on the lattice extension, p. 3 - 66.

à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

5. Unreeve the hoist cable from the hook block and remove it from the lattice extension; Possible reeving methods on the lattice extension, p. 3 - 65.

à

6. Remove anemometer;

à Anemometer on the lattice extension, p. 3 - 68.

7. Remove hoist rope from the head sheave on the 7 m section and guide it to the ground on the lefthadn side of the lattice extension.

H

If the 7 m section needs to be removed and only the 10 m section at the side of the main boom needs to be folded, proceed as from point 12.

8. Attach the guide rope to the head of the 7 m section.

9. Remove the locking pins on the left-hand side between 7 m section and 10 m section; Pin connections on the latticeextension, p. 3 - 53.

à

à Swing the 7 m

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10. Swinging the 7 m section in front of the 10 m section; section in front of the 10 m section, p. 3 - 57.

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

11. Move the connection in the middle area 7 m section / 10 m section; 7 m section / 10 m section joint, p. 3 - 45.

à

12. If the 7 m section needs to be removed, attach 7 m section on auxiliary crane, remove all locking pins between the 7 m section and the 10 m section and place 7 m section on a separate vehicle.

13. Fold in both deflection sheaves on the 10 m section; the deflection sheaves on the 10 m section, p. 3 - 61.

à Folding out / in

14. Reel hoist cable up to the main boom head.

15. Attach the guide rope to the head of the 10 m section.

16. Remove left-hand locking pin between the 10 m section and the main boom head; Pin connections on the main boom head, p. 3 - 49.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

17. Raise the main boom completely; p. 3 - 69.

à Derricking the lattice extension,

18. Swinging the lattice extension onto the main boom; lattice extension when rigging, p. 3 - 56.

à Swivelling the

19. Lower the lattice extension so that it is positioned on the run-up rail.

20. Establish the connection in the front area; p. 3 - 45.

à Establishing a connection,

21. Remove right hand locking pin between the 10 m section and the main boom head; Pin connections on the main boom head, p. 3 - 49.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

22. Swing the lattice extension on the run-up rail onto the main boom; Swivelling the lattice extension when rigging, p. 3 - 56.

à

23. Secure the connection in the front area; p. 3 - 43.

H

à Securing the connection,

If the 7 m section has been removed, proceed from point 25.

24. If the 7 m section has been removed, establish a connection between the 10 m and the main boom; Connection between 10 m section and main boom, p. 3 - 48.

à

25. Remove electrical connection between the lattice extension and the 10 m swing-away lattice extension, p. 3 - 58. main boom;

à

26. Disconnect hydraulic connection between the lattice extension and the main boom; Establishing/disconnecting the hydraulic connection, p. 3 - 60.

à

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

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à

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Two-stage swing-away lattice extension (additional equipment) 3.5 Checklists for rigging work

28. Folding in the run-up rail;

à Folding the run-up rail out/in, p. 3 - 41.

29. If necessary, remove hose drum connection for hydraulic supply ; Hose drum for hydraulic supply, p. 3 - 38.

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à

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6

Description of rigging work

3.6.1

Preparing the truck crane for rigging

H

The data in this section also applies to the rigging of the boom extension.

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

If the following prerequisites are met, lowering into the horizontal position with lattice extension/boom extension and a slewing range of 360° is permitted and is monitored by the SLI; Raising and setting down the main boom with rigged lattice extension, p. 3 - 71.

à

Requirements for rigging

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

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

– The truck crane is supported by the outrigger span required acc. to the lifting capacity table for the planned operation with the lattice extension and is aligned horizontally.

– The main boom is completely retracted and has been lowered into horizontal position.

– The telescoping cylinder is locked in telescopic section IV and is retracted as far as possible just before the start of rigging so that all telescoping parts are fully retracted.

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

Requirements for unrigging

Before you lower a lattice extension or the boom extension into a horizontal position, the following requirements must be met: – No other load is raised apart from the hook block.

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

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

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

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

– The telescoping cylinder is locked in telescopic section IV and is retracted as far as possible just before the start of rigging so that all telescoping parts are fully retracted.

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

Securing lattice extension with cord

If the truck crane is not well aligned, the lattice extension may swing out of its own accord when you remove the last connection that held the lattice extension at the side of the main boom.

You must therefore secure the lattice exension before you begin with the rigging work.

G

Risk of accidents from lattice extension swinging of its own accord!

Always secure the lattice extension with a guide rope on the main boom before removing any connections.

This will prevent the lattice extension from slipping off the run-up rail, swinging around and knocking you off the carrier or injuring other persons in the slewing range.

Secure the lattice extension as follows:

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

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

• Have a helper hold the cord tight whilst you are removing the last connection.

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H

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

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.2

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

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

S

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

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

Only then is the lattice extension secured against slipping.

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

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

– Before installation and before rigging the lattice extension.

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

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

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Transport condition with lattice extension folded at the side

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

• Check the connections and establish them if necessary.

If 7 m section and 10 m section are folded at the side: – The 10 m section is locked at the slewing axle (1) in front on the main boom and the slewing axle is secured with a retaining pin (2); Establishing a connection, p. 3 - 45, Securing the connection, p. 3 - 43.

à à

– The pins (4) are inserted on the pivot point between the 7 m section and Connection on the pivot point, p. 3 - 54. the 10 m section;

à

– The connection (7) in the middle area is in the position 7 m section / 10 m section; 7 m section / 10 m section joint, p. 3 - 45.

à

– The connection (5) between 7 m section and main boom in the rear area is established ; Connection between 7 m section and main boom, p. 3 - 47.

à

If the 10 m section only is folded at the side: – The 10 m section is locked at the slewing axle (1) in front on the main boom and the slewing axle is secured with a retaining pin (2); Establishing a connection, p. 3 - 45, Securing the connection, p. 3 - 43.

à à

– The connection between the 10 m section and the main boom in the rear Connection between 10 m section and main boom, area is established (6); p. 3 - 48.

à

If the 7 m section only is folded at the side: – The connection in the middle area is in the position 7 m section / main boom (3); 7 m section / main boom joint, p. 3 - 46.

à

– The connection between 7 m section and the main boom in the rear area Connection between 7 m section and main boom, p. 3 - 47. is established;

à

Transport condition with removed lattice extension

The transport condition for the removed lattice extension is established when all of the following connections have been made.

• Check the connections and establish them if necessary.

– The connections on the pivot point between the 7 m section and the 10 m section have been established (4); Connection on the pivot point, p. 3 - 54.

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à

– The connection in the middle area is in the position 7 m section / 10 m section (7); 7 m section / 10 m section joint, p. 3 - 45.

à

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.3

Hose drum for hydraulic supply The hydraulic supply for the lattice extension is provided through a hose drum on the left-hand side of the main boom.

If the main boom is used for longer periods of time, the hose drum's hydraulic connections should be brought into the Main boom operation position.

This prevents unnecessary reeling and unreeling of the hose.

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

à Locking device for transportation,

– Hydraulic connection, Working with the lattice extension position and main boom operation position; Hydraulic connection, p. 3 - 39.

à

Locking device for transportation

G

The hose drum is equipped with an anti-twist device. The anti-twist device prevents the hose drum twisting unchecked against the holder when releasing the strain relief because of initial tension.

Risk of accidents from uncontrolled turning of hose drum.

You may release the anti-twist device only when you have attached the strain relief on the main boom beforehand. By doing this you prevent the hose drum from twisting uncontrollably against the holder and the turning hydraulic hoses injuring other people.

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

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

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

There are eight bores (1) distributed over a the radius on the inner flanged wheel (2) of the hosedrum.

Inserting anti-twist device

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

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

Removing anti-twist device

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

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

Hydraulic connection

G

Before operating the lattice extension, you must establish the hydraulic connection. Before working with the main boom for longer periods, you must disconnect the hydraulic connections.

Risk of accidents from hydraulic hoses springing back!

If you detach the strain relief after the anti-twist device has been released, do not under any circumstances let go of the strain relief before it has been re-attached. If you let go of the strain relief, the hydraulic hoses will spring back uncontrolledly due to the spring force in the hose drum and may injure persons or damage parts of the truck crane.

Position for working with the lattice extension

• Take the strain relief out of the holder (1) and pull the hydraulic hoses (2) towards the main boom head.

• Hook the strain relief onto the holder (3).

• Guide the hydraulic hoses through the

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guide rollers (4).

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Position for working with the main boom

• Remove the hydraulic hoses from the guide rollers (4).

• Release the strain relief (2) on the holder (3)

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and attach the strain relief to the holder (1).

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.4

Folding the run-up rail out/in The run-up rail is folded out for rigging and folded back in for on-road driving after derigging.

Folding out the run-up rail

• Unscrew the spring latch (2).

• Fold out the run-up rail (3) until the locking bar (1) engages in the bore hole (4).

Folding in the run-up rail

• Pull the locking bar (1) downwards against the spring force, and out of the bore hole (4).

• Fold out the run-up rail (3) to a small extent and let go the locking bar (1).

• Fold in the run-up rail completely.

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• Secure the run-up rail with the spring latch (2).

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.5

Connections with folded lattice extension The lattice extension is turned sideways to the main boom in the folded position.

In this position there are four areas on the main boom basic section, where various connections have to be disconnected and reconnected again during rigging and unrigging: – in the front area (1), in front of the locking point at 100%, – in the middle area (2), in front of the locking point at 50%, – in the rear area (3), over the side panelling.

In each area there are bearing points that can be used for establishing connections. Depending on the rigging mode and job, different parts of the lattice extension must be connected to each other or connected to the main boom basic section.

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G

Risk of accidents due to falling parts.

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

This prevents unsecured pins from becoming loose, falling out and causing injuries.

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Connections in the front area

In the front area there is a connection between the 10 m section and the main boom.

This connection needs to be established if the lattice extension is folded at the side of the main boom during unrigging or installation.

The connection must be disconnected when the lattice extension is being rigged or removed.

The connection is made of retaining pins (3), slewing axle (1) at the basic section and the holders (2) at the 10 m section.

For removing the connection, the 10 m section is derricked on the slewing axle.

For establishing the connection, the 10 m section is locked in the slewing axle and is secured with locking pins.

Securing the connection

• Swing the lattice extension on the run-up rail onto the main boom until the bores (1) on the 10 m section and the main boom are aligned.

• Release the retaining pin and remove the locking pin (2) from the holder (3).

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

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G

Risk of accidents from a falling lattice extension.

The locking pin prevents mechanical pressing down of the slewing axle and secures the 10 m section to the main boom. Therefore, always secure the laterally folded lattice extension in the front area with the locking pin.

This will prevent the lattice extension (e.g. for main boom operation) from sliding from the slewing axle and falling.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

G G

Removing the connection Risk of accidents from a falling lattice extension.

Before removing the connection ( p. 3 - 50) ensure that the 10 m section is pinned on the main boom head.

This will prevent the lattice extension from falling and causing injury to you or other persons.

à

Risk of accidents from lattice extension swinging of its own accord.

Always secure the lattice extension with a guide rope on the main boom before derricking out the lattice extension from the slewing axle.

This will prevent the lattice extension from slipping off the run-up rail, swinging around and knocking you off the carrier or injuring other persons in the slewing range.

• Secure the lattice extension with a guide rope; à p. 3 - 34.

• Remove the locking pin (4) from the bore hole (3) and secure it in the holder (5) with a retaining pin.

• Derrick the lattice extension fully on one of the control units;

à p. 3 - 69.

• Check, if the holder (2) on the 10 m section is fully derricked downwards from the slewing axle (1).

If the slewing axle is still parly in the holder, then you must push it downwards mechanically:

• Lift the lever (6) against the spring force and hold it in the bracket (5).

During this, the slewing axle (1) is pressed downwards.

• Swing the lattice extension outward until the bracket (2) is no longer above the slewing axle (1).

• Lift the lever sideways from the bracket and

With this, the connection is in the correct position for next unrigging.

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Operating instructions lattice extension GMK 4075

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slowly yield to the spring force. Once again the slewing axle is pressed upwards.

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Establishing a connection

• Place the lattice extension on the run-up rail.

• Check if the locking pin (4) is pulled out of the bore hole (3).

• Check, if the lever (7) is under the bracket (6).

• Swing the lattice extension on the run-up rail sideways onto the main boom.

First the slewing axle (1) is pressed down by the holder (2) and then it is locked in the holder.

• Check if the slewing axle projects upwards from the bracket.

• Remove the locking pin (4) from the holder (5), insert it in the bore holes (3) and secure it with the retaining pin.

Connections in the middle area

When connecting in the middle area, three different joints can be established: – 7 m section / 10 m section joint, – 7 m section / main boom joint, – Joint at the 10 m section

7 m section / 10 m section joint This joint has to be established:

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– when rigging the 17 m two-stage swing-away lattice extension – before the lattice extension is swung onto the main boom head, – when rigging the 17 m two-stage swing-away lattice extension – after the 7 m section was folded onto the 10 m section, – when rigging the 10 m swing-away lattice extension – after the 10 m swing-away lattice extension was swung sideways onto the main boom, – before removing the two-stage swing-away lattice extension.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

• Fasten the locking bar (1) with a pin (2) onto the 10 m section and with a pin (3) onto the 7 m section.

• Secure both the pins, each with one retaining pin.

7 m section / main boom joint This joint has to be established: – when rigging the 10 m swing-away lattice extension – before the lattice extension is swung onto the main boom head, – before removing – when only the 10 m section is supposed to be removed.

• Fasten the locking bar (1) with a pin (3) onto the 7 m section and with a pin (2) onto the 7 m section.

• Secure both the pins, each with one retaining pin.

Joint at the 10 m section This joint has to be established: – when rigging the 17 m two-stage swingaway lattice extension. – before the 7 m section is folded before 10 m section.

– Before operating with the 10 m swing-away lattice extension, if the 7 m section is removed.

• Fasten the locking bar (1) with a pin (2) and • Secure both the pins, each with one retaining pin.

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Operating instructions lattice extension GMK 4075

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(3) onto the 10 m section.

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Connections in the rear area

Connection between 7 m section and main boom The connection must be made: – when unrigging of the 17 m two-stage swing-away lattice extension, – for operation with the 10 m swing-away lattice extension.

The connection must be removed: – when rigging the 17 m two-stage swing-away lattice extension, – for unrigging the 17 m two-stage swing-away lattice extension.

G

Removing the connection Risk of accidents from falling 7 m section.

Make sure the connection is established at the pivot point between the 7 m section and the 10 m section ( p. 3 - 53), before you remove the connection between the 7 m section and the main boom.

This will prevent the 7 m section from falling down when releasing the connection.

à

• Release the retaining pin and remove the pin (1) from the bearing point (3).

• Insert the pin in the retaining sheet (2) and secure it with a retaining pin.

Establishing a connection

• Swivel the lattice extension into the main boom until the bearing point (3) is aligned.

• Release the retaining pin and take one pin out of the retaining sheet (2).

• Insert the pin into the bearing points (3) and

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secure it with a retaining pin.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Connection between 10 m section and main boom

H

This connection does not apply to truck cranes that are supplied with an 17 m two-stage swing-away lattice extension.

This connection must be established if the 10 m swing-away lattice extension is folded in to the side during unrigging.

The connection must be removed before the 10 m swing-away lattice extension is swivelled onto the main boom head, when the 7 m section is uninstalled.

If the truck crane was delivered only with a 10 m swing-away lattice extension (without 7 m section), the connection between the 10 m section and the main boom is established using a retaining strut with two pins.

G

Removing the connection Risk of accidents from falling 10 m section.

Ensure that the connection in front area is established and is secured; p. 3 - 43.

This will prevent the 10 m section from falling down when releasing the connection.

à

• Loosen the retaining pin and remove the pins (3) from the bearing points (2).

• Remove the retaining strut.

• Stow the retaining strut and the pins with the retaining pins for operation (e.g. in the storage box).

Establishing a connection Correct original position is reached, when the connection in front area is established and is secured; p. 3 - 43.

à

• Put the retaining strut (1) onto the bearing point (2) on the main boom and 10 m section.

• Fasten the retaining strut with pins (3) and 20.02.2001

secure the pin with retaining pins.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.6

Pin connections on the main boom head The lattice extension and main boom head are connected on the bearing points using pins. The pins can be found in holders on the lattice extension and are secured there with retaining pins.

G G G

Risk of accidents due to falling parts.

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

Risk of accidents from lattice extension swinging of its own accord.

Always secure the lattice extension with a guide rope before removing any connections.

This will prevent the lattice extension from swinging around of its own accord and causing injury to you or other persons.

Risk of accidents from a falling lattice extension.

Ensure that the connection in the front area is established, before you release the connection on the right side of the main boom head. This will prevent the lattice extension from falling and causing injury to you or other persons.

Connections on the left side The connection needs to be established after the lattice extension has been swivelled in front of the main boom head during rigging.

The connection has to be removed so that the lattice extension can be swivelled onto the main boom side during unrigging.

Connections on the right side The connection needs to be established so that the lattice extension can be swivelled in front of the main boom head for rigging.

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The connection needs to be removed so that the lattice extension can be swivelled onto the main boom when it is on the run-up rail during unrigging.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Establishing connections

For these connections you will find are three short pins and one long pin in holders on the fixed part of the 10 m section.

Connections on the right side

• Swing the lattice extension onto main boom head, until the bearing points (1) and (4) are in alignment.

• Remove the retaining pins and take the two pins (2) and (5) out of the holders (3).

• Insert the two pins into the bearing points (1) and (4) and secure them with retaining pins.

Connection on the left side

• Swing the lattice extension in front of the main boom head, until the bearing points (1) and (2) are in alignment.

• Remove the retaining pins from the pins in the holders (5).

• First, insert the pin (3) in the upper bearing point (1).

• Then insert the long pin (4) into the bottom bearing point (2). If the bearing points do not align, you can take the weight off the bearing points; Relieving the load on bearing points, p. 3 - 52.

à

• Use retaining pins to secure the pins in the

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bearing points.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Connections remove

Secure the lattice extension with a guide rope before removing any connections.

Connections on the left side

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

• First hammer the pin (4) out of the lower bearing point (2). If the pin cannot be hamRelieving mered out, you can unload it; the load on bearing points, p. 3 - 52

à

• You may then hammer the pin (3) out of the upper bearing point (1).

• Insert both pins into the holders (5) and secure them with retaining pins.

G

Connection on the right side Risk of accidents from a falling lattice extension.

Ensure that the connection in the front area is established, before you release the connection on the right side. This will prevent the lattice extension from falling and causing injury to you or other persons.

• Swing the lattice boom onto the main boom, and establish the connection in the front area; p. 3 - 45.

à

• Remove the retaining pins from pins (2) and (5) in the bearing points (1) and (4).

• Hammer the two pins out of the bearing points.

• Insert both the pins (2) and (5) into the hold-

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ers (3) and secure them with retaining pins.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Relieving the load on bearing points

The dead weight of the lattice extension can cause the bearing points on the left side to be misaligned or the pins to get weighted which makes it impossible to knock them out.

When establishing or disconnecting the connections proceed as follows:

• Lower the lattice extension until it is on the ground with the supports (1) (if necessary, override the lifting limit switch).

• Continue to lower carefully until the connecting points (2) align or until the load has been removed from the pins; Derricking the lattice extension, p. 3 - 69.

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à

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.7

Pin connections on the latticeextension The 10 m section and the 7 m section are connected on the bearing points using pins. The pins are inserted into the 7 m section, at the rear of the retaining sheet on the upper boom.

G G G

Risk of accidents due to falling parts.

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

Risk of accident due to 7 m section swinging of its own accord.

Always secure the 7 m section with a guide rope before removing any connections.

This will prevent the 7 m section from swinging around of its own accord and causing injury to you or other persons.

Risk of accidents from falling 7 m section.

Be sure that the connections between the 7 m section and the main boom (in the rear area) and between the 7 m section and the main boom have been made before you release the connection on the right side of the pivot point. In this way, you prevent the 7 m section from falling when this connection is released and causing injury to you or others.

Connection on the left side The connection needs to be established after the 7 m section has been swivelled in front of the 10 m section during rigging.

The connection needs to be removed so that the 7 m section can be folded at the side of the 10 m section during unrigging.

Connection on the pivot point, on the right side

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This connection must be established if the 10 m swing-away lattice extension is unrigged and the 7 m section is attached to the main boom.

This connection must be removed if the 10 m swing-away lattice extension is rigged and the 7 m section is attached to the main boom.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Connection on the left side

• Swivel the 7 m section in front of the 10 m section until the bearing points on the left side are in alignment. If necessary, you can unload the bearing points in the same way, as in the case of pin connections on the main boom; Relieving the load on bearing points, p. 3 - 52.

à

Establishing a connection

• Loosen the retaining pins and remove the pins from the retaining sheet (1).

• Insert the two pins into the bearing points (2) and (3) on the left side and secure the pins with retaining pins.

Removing the connection

• Remove the retaining pins and take pins out of the bearing points (2) and (3) on the left side.

• Insert both pins into the top of the retaining sheet (1) and secure them with retaining pins.

Connection on the pivot point

Before removing this connection, the connections between the 7 m section and the main boom in the rear area must be established ( p. 3 - 47) and the connection in the middle area must be in position 7 m section / main boom ( p. 3 - 47).

à

à

Removing the connection

• Remove the retaining pins and pull the pins (2) and (4) out of bearing points (3) and (5).

• Insert both pins into the retaining sheet (1) and secure them with retaining pins.

Establishing a connection

• Remove the retaining pins and take the conical pin (4) and another bolt (2) out of the retaining sheet (1).

• Insert the two pins into the bearing points (3) and (5), the conical pin (4) is designed for the lower bearing point.

H 3 - 54

Always insert the conical pin in the lower bearing point, so that you can knock it down while removing the connection.

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• Secure the pins using retaining pins.

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.8

Swinging the lattice extension onto the main boom head This section describes slewing the lattice extension – onto the main boom head when rigging and – onto the main boom basic section when unrigging.

The lattice extension must be swung out of the transport position onto the main boom head so that the 10 m section can be fastened to the right side of the main boom head with pins.

Prerequisites

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

– The required connections among the individual lattice extension sections or the lattice extension sections and the main boom have been removed.

à

Swinging the lattice extension When swung, the lattice extension rolls on the run-up rail, turns around the connection in the front area (2) and makes contact at the front at the bearing points (1).

• When rigging pull the lattice extension at the back away from the basic section until it is at the front and the bearing points (1) are aligned.

• When unrigging push the lattice extension onto the run-up rail until the connection in the front area is ensured. Secure the connection with the reSecuring the connection, p. 3 - 43. taining pins;

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à

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.9

Swivelling the lattice extension when rigging

H

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

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

When rigging the 10 m swing-away lattice extension and the 17 m two-stage swing-away lattice extension, you have to swing the 10 m section in front of the main boom head.

When rigging the 17 m two-stage swing-away lattice extension, you must also swing the 7 m section in front of the 10 m section.

G Swinging the 10 m section in front of the main boom

Danger of accident due to lattice extension turning of its own accord!

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

Prerequisites: – The lattice extension has been swivelled onto the main boom head; Swinging the lattice extension onto the main boom head, p. 3 - 55.

à

– The 10 m section is fastened to the right side of the main boom head; Pin connections on the main boom head, p. 3 - 49.

à

– The lattice extension is secured on the head of the 10 m section with a Securing lattice extension with cord, p. 3 - 34. guide rope;

à

• Disconnect the connection between the 10 m section and the main boom;

à Removing the connection, p. 3 - 44.

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

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

• Carefully lower the lattice extension from the control unit on the foot of the 10 m section until it starts to swing out.

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

If you are alone and when securing you fixed the guide rope to the crane, the lattice extension turns only so far until the guide rope is taught. You can now turn the lattice extension with the guide rope in front of the main boom head.

Proceed in the opposite order for unrigging.

Swing the 7 m section in front of the 10 m section

Prerequisites: – The 10 m section is locked in front of the main boom head; connections, p. 3 - 50.

à Establishing

– The lattice extension is secured on the head of the 7 m section with a guide rope;

• Move the connection in the on 10 m section middle area; à Joint at the 10 m section, p. 3 - 46.

• Turn the 7 m section using the guide rope in front of the the 10 m section.

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Proceed in the opposite order for unrigging.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.10

Electrical connections on the lattice extension The SLI, the lifting limit switch and the lowering limit switch are connected via the electrical connection on the lattice extension.

10 m swing-away lattice extension

For the 10 m swing-away lattice extension the electrical connection is made or disconnected on the right side of the main boom head.

Establishing the electrical connection

• Remove the short-circuit plug (3) from the socket (4) on the main boom and plug it in the dummy socket (5).

• Unwind the cable from the roll (6).

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

Disconnecting electrical connection

• Remove the plug (2) from the socket (4) on the main boom head and insert it in the dummy socket (1) on the 10 m section.

• Remove the short-circuit plug (3) from the dummy socket (5) and plug it in the socket (4) on the main boom.

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• Wind the cable onto the take-up reel (6).

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

• Check if the dummy plug (2) is inserted in the socket (1) at the front of the 10 m section.

17 m two-stage swing-away lattice extension

For the 17 m swing-away lattice extension an additional connection is made or disconnected between the 10 m section and the 7 m section as well as the electrical connection of the 10 m swing-away lattice extension.

• First make the electrical connection for the 10 m swing-away lattice extension;

à p. 3 - 58.

Establishing the electrical connection

• Remove the plug (3) from the dummy socket (1) on the 7 m section.

• Unwind the cable from the roll (5).

• Remove the dummy plug (2) from the socket (4) on the 10 m section and insert it in the dummy socket (1) on the 7 m section.

• Insert the plug (3) in the socket (4) on the

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10 m section.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Disconnecting electrical connection

• Remove the plug (3) from the socket (4) on the 10 m section.

• Remove the dummy plug (2) from the dummy socket (1) on the 7 m section and insert it in the socket (4) on the 10 m section.

• Insert the plug (3) in the dummy socket on the 7 m section.

• Wind the cable onto the take-up reel (5).

3.6.11

Establishing/disconnecting the hydraulic connection The hydraulic supply is required for derricking the lattice extension. Before establishing the connection, the connections on the hose drum must be in Hose drum for hydraulic supply, the working with the lattice extension position; p. 3 - 38.

à

S

Risk of damage to hydraulic hoses!

When establishing the connection, always move the hoses right out of the 10 m section. If the hoses are moved out of the front of the 10 m section, they will be damaged if the lattice extension turns.

Establishing the hydraulic connection

• Take the hose line (2) out of the holders (3) on the 10 m section and remove the protective cap.

• Pull the hose lines right out of the 10 m section and guide the hose lines to the left side of the main boom head.

• Remove the protective caps from the quick

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couplings (1) and connect the hose lines there (observe colour code).

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Remove the hydraulic connection

• Remove the hose pipes (2) from the quick couplings (1) on the main boom head.

• Seal the quick couplings with the protective caps.

• Squeeze the hose pipes into the holders (3) on the 10 m section.

• Close the hose ends with the protective caps.

3.6.12

Folding out / in the deflection sheaves on the 10 m section To prevent the hoist rope dragging on the main boom or lattice extension during operation with the lattice extension or boom extension, the hoist rope is guided via deflection sheaves.

On the 10 m section there is a deflection sheave at the rear (1) and a deflection sheave at the front (2).

Both sheaves must be folded out: – for operation with the 10 m swing-away lattice extension, – for operation with the 17 m two-stage swing-away lattice extension.

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For transportation both deflection sheaves must be folded in.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Folding rear deflection sheave

G

Risk of crushing.

Always hold the deflection sheave by the handle, when removing the pin.

You might get your fingers crushed if you hold the sheave by the side plate.

Folding out deflection sheave

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

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

• Secure the pin with a retaining pin.

Folding in deflection sheave

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

• Fold the deflection sheave down and insert the pin in the bore (1).

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• Secure the pin with a retaining pin.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Folding front deflection sheave

G

Risk of crushing.

Always hold the deflection sheave by thestrut on the top when removing the pin. You might get your fingers crushed if you hold the sheave by the side plate.

Folding out deflection sheave

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

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

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

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

Folding in deflection sheave

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

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

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

• Insert the pin through the bore and secure it

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with a retaining pin.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.13

G

Positioning/removing the hoist cable Risk of accidents due to falling parts.

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

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

10 m swing-away lattice extension (33 ft swing-away lattice extension)

17 m swing-away lattice extension (56 ft swing-away lattice extension)

Positioning hoist cable

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

• Guide the hoist rope via the deflection sheaves (4), (3) and via the head sheave (2) on the 10 m section or on the 7 m section.

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

• Attach the hook tackle or the hook block. The hoist rope may now, depending on the length of lattice extension, be reeved once or twice; p. 3 - 65.

à Removing hoist cable

• Unreeve the hook block.

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

• Take the hoist cable off the head sheave (2) and the deflection sheaves (4), • Put all hoist cable holding rollers and rods back in place and secure these with retaining pins.

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(3) and place it onto the ground on the left side.

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

Possible reeving methods on the lattice extension

The hoist cable can be reeved once or twice.

Hook tackle, max. lifting capacity: 8 t maximum load bearing capacity with GMK 4075: Single reeving 5 t (11,000 lbs)

1-sheave hook block, max. load bearing capacity 20 t

1 fall

1 fall

2 fall

maximum load bearing capacity with GMK 4075: for simple reeving 5 t (11,000 lbs) for two falls reeving 10 t (22,000 lbs)

The hoist rope can be reeved a maximum of two falls on the 10 m swingaway lattice extension.

On the 17 m two-stage swing-away lattice extension and on the 22/27m boom extension the hoist cable can only be reeved once.

à Operating instructions GMK 4075, Part 2 Superstructure – Rigging work main boom.

Reeving the hoist rope in the hook block;

• Fasten with a 2-fall reeving, the rope end clamp on the attachment plate

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(1), in front on 10 m section..

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.14

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

H Overriding connection on main boom

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

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

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

The connection is now overridden.

On 10 m swingaway lattice extension

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

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

• Connect the lifting limit switch on the socket (1).

circuit plug (2) back in the socket (1).

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• When unrigging you must insert the short-

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

On the 17 m twostage swing-away lattice extension

H

For operation with the 17 m two-stage swing-away lattice extension the connection for the lifting limit switch on the 10 m section must be overridden with a short-circuit plug.

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

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

• When unrigging close the socket (3) with the

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protective cap.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.15

Anemometer on the lattice extension

H

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

On 10 m swingaway lattice extension

• Attach the anemometer (3) to the holder (2) on the head of the 10 m section and secure it with a retaining pin.

• Insert the plug (1) of the connecting cable in the distribution box on the head of the 10 m section.

• Check for freedom of movement.

The anemometer must return to a vertical position after being swung outwards.

• When unrigging close the socket on the distribution box with the protective cap.

On the 17 m twostage swing-away lattice extension

• Attach the anemometer (1) to the holder (2) on the head of the 7 m section and secure it with a retaining pin.

• Insert the plug (3) of the connecting cable in the distribution box on the head of the 7 m section.

• Check for freedom of movement.

The anemometer must return to a vertical position after being swung outwards.

• When unrigging close the socket on the dis-

H 3 - 68

You must remove the anemometer before unrigging the lattice extension.

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tribution box with the protective cap.

Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.16

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

When rigging

To derrick the lattice extension when rigging there are two control units each with two pushbuttons on the 10 m section.

• To raise press the top push-button raise lattice extension (1).

• To lower press the bottom push-button lower lattice extension (2).

During operation

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

The lattice extension can be derricked, only when the derricking gear for the lattice extension is switched on.

When the derricking gear is switched on:

z = z

– the indicator lamp in the rocker switch derricking lattice extension on / off lights up brightly and – is shown on the display crane control and in the main menu the indicator lamp derricking lattice extension on / off lights up green.

• If necessary, switch on the derricking gear of the lattice extension, for this once press the rocker switch derricking lattice extension on / off.

To raise press the right control lever to the left.

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To lower press the right control lever to the right.

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Two-stage swing-away lattice extension (additional equipment) 3.6 Description of rigging work

3.6.17

G

Transportation on a separate vehicle Risk of accidents from a falling lattice extension.

Only attach the lattice extension in such a way that it is positioned in the centre of gravity and always use lifting gear with sufficient lifting capacity.

This prevents the lattice extension from falling and injuring people while Centres of gravity for slinging, p. 3 - 8. loading;

à

• Check if all the required connections for transport condition are established;

à Transport condition with removed lattice extension, p. 3 - 37.

• For transportation, place the lattice extension on the skid (1) at the front and onto the lower cross strut (2) at the rear of the 10 m section.

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

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S

Risk of damaging the lattice extension!

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

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.7 Raising and setting down the main boom with rigged lattice extension

3.7

Raising and setting down the main boom with rigged lattice extension

H H

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

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

For raising and lowering, the following prerequisites must be fulfiled:

00== !

– The SLI code for the actual rigging mode is set on the SLI with the rigged lattice extension; Operating instructions GMK 4075, Part 2 Superstructure – Crane operation.

à

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

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

• Derrick in the main boom to raise.

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• Derrick out the main boom to set down.

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Two-stage swing-away lattice extension (additional equipment) 3.7 Raising and setting down the main boom with rigged lattice extension

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.8 Telescoping with rigged lattice extension

3.8

S H

Telescoping with rigged lattice extension The main boom may become overloaded!

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

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

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

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

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

à

capacity table).

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

• Set down the load.

• Derrick in the main boom by the appropriate angle according to the rigging program (

à Rigging program in the lifting capacity table).

• Telescope the main boom by the required length, taking into account the

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hook block; lower or raise it using the hoist.

Do not actuate the slewing gear when telescoping.

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Two-stage swing-away lattice extension (additional equipment) 3.8 Telescoping with rigged lattice extension

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.9 Operation with the lattice extension

3.9

Operation with the lattice extension

H

G H H 3.9.1

The information in this section also applies to operation with the boom extension. Observe the following safety instruction before working with the boom extension.

Risk of overturning when working with the boom extension!

No hook block may be reeved on the main boom during operation with the boom extension.

It is not permitted to work with the main boom if the boom extension is rigged.

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

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

à

SLI shutdown The operation with the lattice extension and the boom extension is monitored by the SLI. SLI shutdowns can occur during lattice extension operation for the same reasons as with main boom operation; Operating instructions GMK 4075, Part 2 – Crane operation.

à

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If you have entered a SLI code for a lifting capacity table with a certain angle of the lattice extension, SLI releases the given load only then, when the lattice extension is derricked to this angle in advance.

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Two-stage swing-away lattice extension (additional equipment) 3.9 Operation with the lattice extension

3.9.2

Procedure if the permissible wind speed is exceeded Strong winds can overstrain the truck crane. Therefore, closely observe the Operating instructions instructions in the Effect of wind on crane operation, GMK 4075, Part 2 – Crane operation.

à

If the maximum permissible wind speed according to the lifting capacity table is exceeded during the main boom operation, proceed as follows: with wind speed up to 20 m/s

with wind speed over 20 m/s

• Set down the load.

• Slew the superstructure so that

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the main boom creates as little wind resistance as possible.

• Set down the load.

• Fully retract the main boom.

• Set down the lattice extension.

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Two-stage swing-away lattice extension (additional equipment) 3.10 Turning loads with the lattice extension

3.10

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

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

G G H 3.10.1

Risk of accidents due to overloading.

Lifting a load with two hooks is permissible only if the following instructions and illustrations are observed.

If these instructions are not observed, accidents could occur due to individual parts of the truck crane being overloaded. The SLI then no longer provides protection.

Two-hook operation with the boom extension is not permitted!

Risk of accidents due to overloading.

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

You can find the position and function of the required operating instruments in the supplied Operating instructions of the GMK 4075.

Prerequisites The following description requires that: – the main hoist cable is reeved on the main boom

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– the auxiliary hoist rope is reeved on the lattice extension and

G

– the lifting limit switches for both hoists are connected.

Risk of accidents due to overloading.

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

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

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Two-stage swing-away lattice extension (additional equipment) 3.10 Turning loads with the lattice extension

3.10.2

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

H äå 32 ä

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

• Switch off both hoists.

For this, press down once both the rocker switches main hoist on/off and auxiliary hoist on/off.

Indicator lamps in the rocker switches are dimly illuminated.

When the main hoists are switched off, the main hoist on/off indicator lamp in the main menu on the crane control and auxiliary hoist on/off display lights up red.

• Switch on the main hoist.

Additionally, press the main hoist on/off rocker switch down once. The indicator lamp in the rocker switch lights up brightly.

Lamp I for the main hoist lights up in the Hoists indicator lamps.

• In the display reeving , enter the quantity of reeved cable of the main hoist

§

cable on the main boom.

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

äå

For this, press down once both the rocker switches main hoist on/off and auxiliary hoist on/off.

Indicator lamps in the rocker switches are dimly illuminated.

• Switch on the auxiliary hoist.

Additionally, press the auxiliary hoist on/off rocker switch down once. The indicator lamp in the rocker switch lights up brightly.

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å

• Switch off both hoists.

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Two-stage swing-away lattice extension (additional equipment) 3.10 Turning loads with the lattice extension

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

• In the display reeving, enter the quantity of reeved rope on the auxiliary

4

hoist rope of the lattice extension.

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

ä

Switch on the main hoist.

Additionally, press the main hoist on/off rocker switch down once. The indicator lamp in the rocker switch lights up brightly.

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

11==

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

Now the SLI is set for two-hook operation; this takes into account the reeving for the auxiliary hoist and the lifting capacity table for the lattice extension.

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H

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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Two-stage swing-away lattice extension (additional equipment) 3.10 Turning loads with the lattice extension

Turning a load

S H H

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

Keep the acceleration force as low as possible during two-hook operation.

Therefore move the load at the lowest possible speed!

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

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

C0183

• Lift the load fully with the lattice extension.

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

• Now lift the load with the hook block on the main boom until both slinging

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points are at the same height.

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.10 Turning loads with the lattice extension

C0184

• Slacken the hoist cable on the lattice extension until the load is only hanging from the hook block on the main boom.

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Turning the load is thus completed.

Operating instructions lattice extension GMK 4075 2 084 629 en

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Two-stage swing-away lattice extension (additional equipment) 3.10 Turning loads with the lattice extension

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.11 Driving with rigged crane and installed lattice extension

3.11

Driving with rigged crane and installed lattice extension This section describes how you can move the truck crane with an installed counterweight and rigged lattice extension (e.g. when the lattice extension cannot be rigged on the site due to lack of space).

G G 3.11.1

Risk of accidents!

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

Put the load down before you move the truck crane.

Secure the hook block so that it cannot swing.

Risk of overturning!

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

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

à

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S

Risk of tyre damage!

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

The truck crane may be moved only if tyre pressures are at the prescribed Operating instructions GMK 4075, Part 1 Carrier – Technical data. levels; Do not reduce the tyre pressure!

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Two-stage swing-away lattice extension (additional equipment) 3.11 Driving with rigged crane and installed lattice extension

3.11.2

Boom positions and axle loads

The vehicle may only be moved if certain conditions are met. The boom may have to be moved to a specified position, depending on the installed counterweight.

S

11==

Damage may occur to the axle lines!

Always move the boom to the prescribed position before you move the rigged truck crane. The permitted load on the axle lines will be exceeded if the boom is in a position which deviates from the prescribed position.

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

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

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G

Risk of accidents if SLI is overridden.

Always set the SLI rigging code corresponding to the current rigging mode when you derrick the main boom into the prescribed position. Do not override the SLI; the prescribed positions in the following tables are all within the areas which are permitted according to the lifting capacity tables.

The truck crane safe load indicator does not function when the SLI is overridden!

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.11 Driving with rigged crane and installed lattice extension

10 m swing-away lattice extension

The following table only applies if the 11 m swing-away lattice extension is rigged.

Tables for rigged 17 m two-stage swing-away lattice extension; p. 3 - 86. p. 4 - 25.

Tables for rigged boom extension;

à

à

H Counterweight in t

9.13)

The axle loads specified in the following tables refer to a driving mode with the basic unit and 16 t hook tackle reeved on the lattice extension, hook blocks must be unreeved.

Telescoping Telescope section I/II/III/IV

Main boom angle in °

0/0/0/0

2)

Axle load in t

2)

Axle load x 1000 lbs

Lattice extension angle in °

Main main boom position1

at the front

rear

at the front

rear

)

15

5

front

12.0

12.0

26.5

26.5

0/0/0/0

70

5

rear

12.0

12.0

26.5

26.5

0/0/0/0

15

5

front

11.5

13.0

25.5

29.0

0/0/0/0

70

5

rear

12.5

12.0

27.5

26.5

0/0/0/0

15

5

front

11.0

14.5

24.5

32.0

0/0/0/0

70

5

rear

13.5

12.0

30.0

26.5

0/0/0/0

15

5

front

9.5

18.0

21.0

40.0

0/0/0/0

70

5

rear

15.0

12.5

33.0

27,5

10.1

12.1

16.1

1)Boom

position to the rear:

Boom position at the front: 2)Axle

load front:

Axle load rear:

180° position, boom over driver's cab Each time on the first and the second axle line Each time on the third and the fourth axle line

counterweight version 9.1 t is additional equipment

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3)The

0° position, boom over Truck crane rear edge

s Operating instructions lattice extension GMK 4075 2 084 629 en

3 - 85

Two-stage swing-away lattice extension (additional equipment) 3.11 Driving with rigged crane and installed lattice extension

17 m two-stage swing-away lattice extension

H Counterweight in t

9.13)

The following table only applies if the 17 m two-stage swing-away lattice extension is rigged.

Tables for rigged 10 m two-stage swing-away lattice extension; p. 3 - 85. p. 4 - 26.

Tables for rigged boom extension;

à

à

The axle loads specified in the following tables refer to a driving mode with the basic unit and 8 t hook tackle reeved on the lattice extension, hook blocks must be unreeved.

Telescoping Telescope section I/II/III/IV

Main boom angle in °

0/0/0/0

2)

Axle load in t

2)

Axle load x 1000 lbs

Lattice extension angle in °

Main main boom position1

at the front

rear

at the front

rear

)

15

5

front

12.5

11.5

27.5

25.5

0/0/0/0

70

5

rear

11.5

12.5

25.5

27.5

0/0/0/0

15

5

front

12.5

12.5

27.5

27.5

0/0/0/0

70

5

rear

12.0

12.5

26.5

27.5

0/0/0/0

15

5

front

11.5

14.0

25.5

31.0

0/0/0/0

70

5

rear

13.0

12.5

29.0

27.5

0/0/0/0

15

5

front

13.0

17.5

23.5

38.5

0/0/0/0

70

5

rear

15.0

13.0

33.0

29.0

10.1

12.1

16.1

1)Boom

position to the rear:

Boom position at the front: 2)Axle

load front:

Locking the superstructure and engaging the slewing gear permanent brake

3 - 86

Each time on the third and the fourth axle line

counterweight version 9.1 t is additional equipment

Driving the rigged crane Before the truck crane is moved, the superstructure must be locked to the carrier; Operating instructions GMK 4075, Part 2 Superstructure – Crane operation.

à

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Operating instructions lattice extension GMK 4075

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3.11.3

180° position, boom over driver's cab Each time on the first and the second axle line

Axle load rear: 3)The

0° position, boom over Truck crane rear edge

Two-stage swing-away lattice extension (additional equipment) 3.11 Driving with rigged crane and installed lattice extension

• Lock the superstructure, the lever must point to the left.

H Retracting the outrigger

G

During the following work, you must temporarily switch on and switch off the suspension locking system, which is possible only in the driver's cab. It is therefore recommended to carry out the flowing work from the carrier.

• Retract the outrigger cylinders until the wheels are just above the ground.

Risk of overturning!

Make sure that the truck crane does not overturn when the outriggers are being retracted.

Retract all the outrigger cylinders as uniformly as possible.

Switching over the suspension locking system

u

• Switch the suspension locking system off. To do this push up the suspension locking system rocker switch in driver's cab. The suspension locking system indicator lamp must extinguish.

• Retract the outrigger cylinders until the truck crane is approximately at on-the-road level.

u

down the suspension locking system rocker switch. The suspension locking system indicator lamp lights up when the suspension system is locked.

• Continue to retract the outrigger cylinders. #

Risk of overturning!

To reduce the risk of the crane overturning do not raise the outrigger pads more than 5 to 10 cm off the ground. Leave the outrigger beams extended.

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G

• Switch the suspension locking system back on again. To do this push

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Two-stage swing-away lattice extension (additional equipment) 3.11 Driving with rigged crane and installed lattice extension

Switching on separate steering

S

Before driving with the rigged crane you must switch on separate steering: Damage may occur to steering linkage!

Before driving with the rigged crane always switch on separate steering and steer the truck crane only when the vehicle is moving.

If separate steering is switched off or if you steer with the vehicle stationary the steering linkage may become damaged.

If you drive the truck crane from the driver's cab:

• Switch on the level adjustment system key switch.

C0018

b ?

• Switch on separate steering by releasing the separate steering rocker switch

b

• Turn the third axle line with separate steering rocker switch, until the third

and pressing it down.

The warning lamp steering unlocked illuminates when the steering is unlocked.

and fourth axle lines have the same steering angle.

The connection between the 3rd and 4th axle lines snaps audibly into place and the wheels of the 3rd and 4th axle lines move together.

The steering system is now switched to all-wheel steering.

If you drive the truck crane from the crane cabin:

b

• Press the release separate steering rocker switch downward.

?

The warning lamp steering unlockedilluminates when the steering is unlocked.

This requires pressing the lock button downward.

• Turn the third axle line with separate steering rocker switch in the laft-hand

The connection between the 3rd and 4th axle lines snaps audibly into place and the wheels of the 3rd and 4th axle lines move together.

The steering system is now switched to all-wheel steering.

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Operating instructions lattice extension GMK 4075

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control lever, until the third and fourth axle lines have the same steering angle.

Two-stage swing-away lattice extension (additional equipment) 3.11 Driving with rigged crane and installed lattice extension

S

Driving

H 3

Risk of tyre damage!

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

The truck crane may be moved only if tyre pressures are at the prescribed Operating instructions GMK 4075, Part 1 Carrier – Technical data. levels Do not reduce the tyre pressure!

à

The wind speed must be checked before the rigged truck crane is moved.

The same maximum permissible wind speeds apply as when working with Operating instructions GMK 4075, Part 2 Superstructure – the truck crane; Crane operation.

à

• From the crane cabin switch to driving mode with a load before driving to keep the speed to a minimum. To do this, press down the rocker switch driving with a load; Operating instructions GMK 4075, Part 2 Superstructure – Crane operation – Driving the truck crane from the crane cabin.

à

• Before driving, switch to the starting gear from the driver's cab and switch to manual after starting, whereby you push the switch lever gears once to the left.

This prevents upshifting of the gears and the speed is kept to a minimum; Operating instructions GMK 4075, Part 1 Carrier – Driving the truck crane.

à

Please observe the following points while driving:

• Drive only with a minimum speed.

• The turning radius should be as large as possible when turning corners.

• Steer the truck crane only when it is moving and avoid sudden steering movements.

If the ground is uneven, use the outrigger cylinders to raise the truck crane, Operating instructions GMK 4075, level it horizontally and lower it again; Part 2 Superstructure – Rigging and Part 1 Carrier – Driving the truck crane.

à

Extending the outrigger

à Operating instruc-

Risk of overturning!

The truck crane must be raised until no wheels touch the ground.

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G

Before starting with the crane work, it must be rigged; tions GMK 4075, Part 2 Superstructure – Rigging work.

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Two-stage swing-away lattice extension (additional equipment) 3.11 Driving with rigged crane and installed lattice extension

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.12 Malfunction when working with lattice extension

3.12

Malfunction when working with lattice extension

H

The information in the following table applies to malfunctions during operation with the 10/17 m lattice exension as well as to operation with the 22 / 27 m boom extension.

Malfunction

Cause

Remedy

No function of the lifting limit switch

Lifting limit switch not connected

Connect the lifting limit switch; Lifting limit switch on the lattice extension, p. 3 - 66.

Electrical connection between the boom head and lattice extension and between 10 m section and 7 m section is not established

Establishing electrical connection; 10 m swing-away lattice extension, p. 3 - 58.

Lifting limit switch on the main boom head not overridden

Override the lifting limit switch on the main boom head; p. 3 - 66.

When operating with an 17 m lattice extension or boom extension the short-circuit plug is not inserted on the head of the 12.5 m section.

Insert short-circuit plug; p. 3 - 59.

The main boom cannot be telescoped with the rigged lattice extension or boom extension

The main boom is derricked to such an angle at which telescoping is not permissible

Derrick the main boom to the required angle;

The lattice extension cannot be derricked

Derricking gear of the lattice extension is switched off

à

à

à

à

à Telescoping with rigged lattice extension, p. 3 - 73.

Switch on the derricking gear At of the lattice extension; the control console right, p. 3 - 2.

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à

Operating instructions lattice extension GMK 4075 2 084 629 en

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Two-stage swing-away lattice extension (additional equipment) 3.12 Malfunction when working with lattice extension

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.13 Maintenance work

3.13

Maintenance work

3.13.1

Modules in need of protection during cleaning work

• Provide protection for the following electrical parts during cleaning work: – potentiometer in the joint (1) of the 10 m section – the control box at the rear of the 10 m section (2), – the control box at the front of the 10 m section (3), – the control box at the front of the 7 m section (4) – both the control units (5).

20.02.2001

H

Also observe all instructions contained in the chapter titled Cleaning work of the Maintenance manual.

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3 - 93

Two-stage swing-away lattice extension (additional equipment) 3.13 Maintenance work

3.13.2

Maintenance work M1, monthly

H Pins

For lubricating the pins and support rollers, use the same grease as stated Maintenance in the Maintenance manual for attach pins and socket pins; manual GMK 4075 Maintenance overview – Maintenance Plan M1.

à

Lubricate all attach, securing and retaining pins, in other words – the pins for the pin connection on the lattice extension, – the retaining pins on the return pulleys, – the retaining pins used for fastening the lattice extension sections for transport, – the spring latch on the run-up rail.

H Support rollers

The maintenance interval applies to average operation. Also lubricate the pins after high-pressure cleaning and generally at an interval that will prevent them getting dry.

There are two support rollers on the lattice extension that need to be lubricated.

The two support rollers (1) and (2) are on the bottom of the 10 m section, at the height of the run-up rail.

• Clean the lubricating nipples and insert

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grease into the lubricating nipple with a grease gun.

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Operating instructions lattice extension GMK 4075

Two-stage swing-away lattice extension (additional equipment) 3.13 Maintenance work

Lubricating joint on 10 m section

The joints are lubricated via lubricating nipples.

On either side of 10 m section, there is a lubricating nipple at the (1) pivot point.

• Clean the lubricating nipple and lubricate it with a grease gun.

• Also lubricate the joint on the other side.

Lubricate the derricking cylinder in 10 m section

The derricking cylinder is lubricated via a lubricating nipple.

On the head and foot axle there is one lubricating nipple each (1).

• Clean the lubricating nipple and lubricate it

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with a grease gun.

Operating instructions lattice extension GMK 4075 2 084 629 en

3 - 95

Two-stage swing-away lattice extension (additional equipment) 3.13 Maintenance work

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Operating instructions lattice extension GMK 4075

4 4

Boom extension (additional equipment) . . . . . . . . . . . . . . . . . . . .

4-

1

4.1

Identification and slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

1

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

1 2

4.2

Assembly of boom extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

3

4.3

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

5

CHECK LIST: Rigging the 22 m/27 m boom extension . . . . . . . . . . . . . . . . . . . . 4 CHECK LIST: Unrigging the 22 m/27 m boom extension . . . . . . . . . . . . . . . . . . 4 -

5 9

4.1.1 4.1.2

4.3.1 4.3.2 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.5 4.5.1 4.5.2 4.5.3 4.6

Installing/removing 5 m sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing/removing the two-stage swing-away lattice extension for the boom extension Hydraulic connection at the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical connection at the boom extension. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unfolding/folding the deflection sheave on the 5 m section . . . . . . . . . . . . . . .

Positioning/removing the hoist cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 - 13 44444-

14 15 18 20 21

Driving with rigged crane and rigged boom extension . . . . . . . . . . . . . . . . . . . . . 4 - 23 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23 Boom positions and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26 Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27 Maintenance work M1, monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27

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4.6.1

Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13

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Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.1 Identification and slinging points

4

Boom extension (additional equipment)

4.1

Identification and slinging points

4.1.1

Identification The boom extension consists of the 17 m two-stage swing-away lattice extension and two boom extension sections. The boom extension is designed for the truck crane it was delivered with. The parts which belong to the truck crane have the same serial number as the truck crane.

The following sections are identified by the serial number: – All parts of the 17 m two-stage swing-away lattice extension;

S H

– Both sections of the boom extension (5 m sections).

Operate the truck crane only with those sections of the boom extension which have the same serial number as the crane.

The SLI is only set for this boom extension.

This prevents malfunctions and damage.

For technical reasons a truck crane may only be set with one boom extension.

If you wish to use the boom extension on several GROVE truck cranes, the parts of the boom extension must be adjusted for these cranes and labelled with all of the respective serial numbers.

Have the adjustment of the boom extension only carried out on site by GROVE Customer Support!

20.02.2001

S

à p. 3 - 5.

s Operating instructions lattice extension GMK 4075 2 084 629 en

4-1

Boom extension (additional equipment) 4.1 Identification and slinging points

Serial numbers on the 5 m sections The serial number (1) is on a sheet at the front of the 5 m sections.

4.1.2

G

Slinging points This section shows the slinging points of the 5 m sections.

Attach the sections only to these slinging points because they will then automatically have the correct centre of gravity. Use only lifting gear with Transport dimensions and weights, sufficient load bearing capacity; p. 2 - 1.

à

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The 5 m sections have two slinging points (1) (one slightly offset on each side).

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Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.2 Assembly of boom extensions

4.2

Assembly of boom extensions

22 m boom extension (85 ft boom extension)

7 m section (23 ft section)

10 m section (33 ft section)

5 m section (16 ft section)

27 m boom extension (89 ft boom extension)

5 m section (16 ft section)

H

5 m section (16 ft section)

10 m section (33 ft section)

7 m section (23 ft section)

The lengths of 22 m and 27 m respectively equal the distance between the centre of the locking pin (on the main boom head) and the front edge of the head sheave.

The designations 10 m section, 7 m section and 5 m section have been adjusted to these lengths. The total length of the individual sections is greater or smaller; Transport dimensions and weights, p. 2 - 1.

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à

Operating instructions lattice extension GMK 4075 2 084 629 en

4-3

Boom extension (additional equipment) 4.2 Assembly of boom extensions

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Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.3 Checklists for rigging work

4.3

Checklists for rigging work

4.3.1

CHECK LIST: Rigging the 22 m/27 m boom extension

H

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

Observe the warning and safety information given there!

Prerequisites: – The truck crane is on outriggers or the main boom is placed on the boom support.

– An auxiliary crane is available.

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

à Preparing the truck crane for rig-

2. If the lattice extension is folded up at the side of the main boom, remove the lattice extension; CHECK LIST: Uninstalling (two-stage) swing-away lattice extension, p. 3 - 12.

à

3. If necessary, connect the hose drum for hydraulic supply; for hydraulic supply, p. 3 - 38.

à Hose drum

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

à

5. Install 5 m sections in front of the main boom: One 5 m section for the 22 m boom extension, Both 5 m sections for the 27 m boom extension Slinging points, p. 4 - 2.

Installing/removing 5 m sections, p. 4 - 13.

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à à

s Operating instructions lattice extension GMK 4075 2 084 629 en

4-5

Boom extension (additional equipment) 4.3 Checklists for rigging work

6. Sling two-stage swing-away lattice extension on auxiliary crane; Centres of gravity for slinging, p. 3 - 8.

à

7. Install folded two-stage swing-away lattice extension in front of the 5 m section; Installing/removing the two-stage swing-away lattice extension for the boom extension, p. 4 - 14.

à

8. Attach the guide rope to the head of the 7 m section.

9. Move the connection in the middle area on 10 m section; m section, p. 3 - 46.

10. Swinging the 7 m section in front of the 10 m section; section in front of the 10 m section, p. 3 - 57.

à Joint at the 10

à Swing the 7 m

11. Fasten the 7 m section on left-hand side in front of 10 m section with a pin; Pin connections on the latticeextension, p. 3 - 53.

20.02.2001

à

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Boom extension (additional equipment) 4.3 Checklists for rigging work

12. Establish a hydraulic connection; tension, p. 4 - 15.

13. Establish electrical connections; tension, p. 4 - 18.

à Hydraulic connection at the boom ex-

à Electrical connection at the boom ex-

14. Fold out deflection sheaves of all sections;

à Folding out / in the deflection sheaves on the 10 m section, p. 3 - 61. à Unfolding/folding the deflection sheave on the 5 m section, p. 4 - 20.

15. Place hoist rope on all deflection sheaves and the head sheave of the 7 m section; Positioning/removing the hoist cable, p. 4 - 21.

à

16. Move the anemometer from the head of the main boom to the head of the 10 m section; Anemometer on the lattice extension, p. 3 - 68.

à

17. Move the lifting limit switch from the head of the main boom to the head of the 11 m section; Lifting limit switch on the lattice extension, p. 3 - 66.

20.02.2001

à

s Operating instructions lattice extension GMK 4075 2 084 629 en

4-7

Boom extension (additional equipment) 4.3 Checklists for rigging work

18. Reeve the hoist cable on the hook block; the lattice extension, p. 3 - 65.

à Possible reeving methods on

19. Attach the lifting limit switch weight and guide hoist rope through the weight; Operating instructions GMK 4075, Part 2 Superstructure –

à

Rigging work.

00==

20. SLI code according to the Lifting capacity table for the actual rigging mode of the truck crane with the 22 m or 27 m boom extension.

Operating instructions GMK 4075, Part 2 SuperstrucSet rigging mode

à

ture – Crane operation.

à à

à

20.02.2001

H

Operation with the boom extension is carried out in the same way as for the lattice extension.

Raising the boom; p. 3 - 71, p. 3 - 73, Telescoping; SLI shutdown; p. 3 - 75.

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Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.3 Checklists for rigging work

4.3.2

CHECK LIST: Unrigging the 22 m/27 m boom extension

H

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

Observe the warning and safety instructions given there!

Prerequisites: – The truck crane is on outriggers or the main boom is placed on the boom support.

– An auxiliary crane is available.

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

à Preparing the truck crane for rig-

2. Fully retract and set down the main boom.

00==

3. Enter SLI code according to the Lifting capacity table for the actual rigging mode of the truck crane with the rigged boom extension.

Operating instructionsGMK 4075 part 2, SuperstrucSet rigging mode

à

ture – Crane operation.

4. Remove the lifting limit switch weight and move lifting limit switch from the head of the 7 m section to the head of the main boom; Lifting limit switch on the lattice extension, p. 3 - 66.

à

5. Unreeve the hoist cable from the hook block and remove it from the lattice extension; Possible reeving methods on the lattice extension, p. 3 - 65.

à

à Anemometer on the lattice extension, p. 3 - 68.

20.02.2001

6. Remove anemometer;

s Operating instructions lattice extension GMK 4075 2 084 629 en

4-9

Boom extension (additional equipment) 4.3 Checklists for rigging work

7. Raise the main boom completely; p. 3 - 69.

8. Detach the hydraulic connection; tension, p. 4 - 15.

9. Detach electrical connections; sion, p. 4 - 18.

à Derricking the lattice extension,

à Hydraulic connection at the boom ex-

à Electrical connection at the boom exten-

10. Remove hoist rope and fold in deflection sheaves on all parts of the boom extension; Positioning/removing the hoist cable, p. 4 - 21.

Folding out / in the deflection sheaves on the 10 m section, p. 3 - 61.

Unfolding/folding the deflection sheave on the 5 m section, p. 4 - 20.

à à

à

11. Reel hoist cable up to the main boom head.

20.02.2001

12. Attach the guide rope to the head of the 7 m section.

4 - 10

2 084 629 en

Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.3 Checklists for rigging work

13. Remove the locking pins on the left-hand side between 7 m section and 10 m section; Pin connections on the latticeextension, p. 3 - 53.

à

14. Swinging the 7 m section in front of the 10 m section; section in front of the 10 m section, p. 3 - 57.

à Swing the 7 m

15. Position the central area of the connection 7 m section / 10 m section position,; 7 m section / 10 m section joint, p. 3 - 45.

à

16. Sling two-stage swing-away lattice extension on auxiliary crane; Centres of gravity for slinging, p. 3 - 8.

à

17. Remove folded two-stage swing-away lattice extension from the 5 m section; Installing/removing the two-stage swing-away lattice extension for the boom extension, p. 4 - 14.

à

18. Remove 5 m sections from the main boom: One 5 m section for a 22 m boom extension, Both 5 m sections for a 27 m boom extension Slinging points, p. 4 - 2.

Installing/removing 5 m sections, p. 4 - 13.

20.02.2001

à à

s Operating instructions lattice extension GMK 4075 2 084 629 en

4 - 11

Boom extension (additional equipment) 4.3 Checklists for rigging work

19. If necessary, remove hose drum connection for hydraulic supply; Hose drum for hydraulic supply, p. 3 - 38.

20.02.2001

à

4 - 12

2 084 629 en

Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.4 Description of rigging work

4.4

Description of rigging work

4.4.1

Installing/removing 5 m sections – In order to rig the 22 mboom extension you must install the 5 m section with support roller in front of the main boom head.

– In order to rig the 27 m boom extension you must additionally install the 5 m section without support roller in front of the 5 m section with support roller.

H

An auxiliary crane must be used to install and remove the 5 m sections.

The securing pins (1) for the connection are secured with retaining pins in the holders at the foot of the 5 m sections.

Installing 5 m sections

• Sling the 5 m section with support roller on an auxiliary crane and lift it in front of the main boom head so that the bearing points (2) and (3) align on both sides.

• Insert the securing pins into the bearing points (2) and (3) on both sides.

• Secure all pins with retaining needles.

• Install the second 5 m section in front of the first 5 m section for the 27 m boom extension in the same way.

Removing 5 m sections

• Sling the 5 m section on an auxiliary crane and lift it until the bearing points (2) and (3) are relieved.

20.02.2001

• Release the pins and knock them out of the bearing points (2) and (3) on both sides.

• Insert the pins into the holders at the foot of the 5 m sections and secure them with retaining needles.

Operating instructions lattice extension GMK 4075 2 084 629 en

4 - 13

Boom extension (additional equipment) 4.4 Description of rigging work

4.4.2

Installing/removing the two-stage swing-away lattice extension for the boom extension This section describes the installation and removal of the folded two-stage swing-away lattice extension.

You can also install the folded two-stage swing-away lattice extension in front of a 5 m section (e. g. when you are changing directly from the 17 m two-stage swing-away lattice extension to a boom extension).

H

An auxiliary crane is required to install and remove the two-stage swingaway lattice extension.

The securing pins (1) for the connection are in the holders at the foot of the 10 m sections and are secured with retaining needles.

Installation

• Sling the two-stage swing-away lattice extension onto an auxiliary crane; of gravity for slinging, p. 3 - 8.

à Centres

• Lift the two-stage swing-away lattice extension in front of the 5 m section so that the bearing points (2) and (3) align on both sides.

• Insert the securing pins into the bearing points (2) and (3) on both sides.

• Secure all pins with retaining needles.

Removal

• Sling the two-stage swing-away lattice extension onto an auxiliary crane;

à Centres of gravity for slinging, p. 3 - 8.

• Lift the two-stage swing-away lattice extension until the bearing points are relieved.

• Release the pins and knock them out of the bearing points (2) and (3) on both sides.

• Insert the pins into the holders on the 10 m section and secure them with

4 - 14

20.02.2001

retaining needles.

2 084 629 en

Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.4 Description of rigging work

4.4.3

Hydraulic connection at the boom extension The hydraulic supply is required for derricking the lattice extension. You must re-establish the hydraulic connection of the hose drum if it has been Hose drum for hydraulic detached in order to work with the main boom; supply, p. 3 - 38.

à

Transport condition of the connections

For transport, bring the hydraulic connections always into the following condition.

The hydraulic hoses (5) are in the 5 m section with deflection sheave. For transport, the hydraulic hoses are clamped in the holders (3).

At the two front hose ends there are two quickaction couplings (4) that are attached to a sheet (1). For transport, the sheet is attached in the holder (2) at the front.

20.02.2001

The quick-action couplings (1) are at the rear hose ends (3).

For transport, the hydraulic hoses are clamped in the holders (2).

s Operating instructions lattice extension GMK 4075 2 084 629 en

4 - 15

Boom extension (additional equipment) 4.4 Description of rigging work

At the 22 m boom extension

All connections are made via quick-action couplings. Half couplings which belong together are colour coded.

Establishing a connection

• Connect the rear hose ends (1) of the 5 m section to the quick-action couplings (2) at the main boom head.

• Connect the hydraulic hoses (3) of the 10 m section to the quick-action couplings (4) of the 5 m section at the front.

Disconnecting

• Disconnect all the quick-action couplings and cover them with protective caps.

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• Make the connections ready for transport; à p. 4 - 15.

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Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.4 Description of rigging work

At the 27 m boom extension

All connections are made via quick-action couplings. Half couplings which belong together are colour coded.

Establishing a connection

• Connect the rear hose ends (1) of the 5 m section to the quick-action couplings (2) at the main boom head.

• Detach the hydraulic hose (3) from the holders (4) in the 5 m section with deflection sheave.

• Remove the sheet (6) from the holder (5) and pull the hydraulic hoses through the front 5 m section.

• Attach the sheet (6) in the holder (9) and clamp the hydraulic hoses into the holders (10) in the front 5 m section.

• Connect the hydraulic hoses (7) of the 10 m section to the quick-action couplings (8) of the 5 m section at the front.

Disconnecting

• Disconnect all the quick-action couplings and cover them with protective caps.

• Make the connections of the 5 m sections ready for transport; à p. 4 - 15.

• Clamp the connections of the 10 m section to the holders at the

à p. 3 - 61.

20.02.2001

10 m section;

Operating instructions lattice extension GMK 4075 2 084 629 en

4 - 17

Boom extension (additional equipment) 4.4 Description of rigging work

4.4.4

Electrical connection at the boom extension This section only describes the electrical connections at the 5 m sections.

For establishing the electrical connection at the two-stage swing-away latElectrical connections on the lattice extension, p. 3 - 58. tice extension;

à

Transport condition of the connections

For transport, bring the electrical connections always into the following condition.

There is a cable with a plug (3) at the rear of the 5 m sections.

For transport, the cable is wound around the holders (1) and the plug is inserted in the dummy socket (2).

20.02.2001

There is a plug socket (1) at the front of each 5 m section.

For transport, the sockets are covered with protective caps.

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Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.4 Description of rigging work

At the 22 m boom extension

Establishing a connection

• Connect the cable of the 10 m section to the socket of the second 5 m section at the front.

• Connect the cable of the 5 m section to the socket at the main boom head,

à p. 3 - 58.

Disconnecting

• Detach the electrical connection between 10 m and 5 m section.

• Detach the electrical connection between 5 m section and main boom head;

à p. 3 - 58.

• Prepare the electrical connections at the 5 m section for transport;

à p. 4 - 18.

• Prepare the electrical connections at the 10 m section for transport;

à p. 3 - 58.

At the 27 m boom extension

Establishing a connection

• Connect the cable of the 10 m section to the socket of the second 5 m section at the front.

• Connect the cable of the second 5 m section to the socket of the first 5 m section at the front.

• Connect the cable of the first 5 m section to the socket at the main boom head;

à p. 3 - 58.

Disconnecting

• Detach the electrical connection between the 10 m and front 5 m section.

• Detach the electrical connection between the two 5 m sections.

• Detach the electrical connection between the rear 5 m section and the main boom head;

à p. 3 - 58.

• Prepare the electrical connections at the 5 m section for transport;

à p. 4 - 18.

• Prepare the electrical connections at the 10 m section for transport;

20.02.2001

à p. 3 - 58.

Operating instructions lattice extension GMK 4075 2 084 629 en

4 - 19

Boom extension (additional equipment) 4.4 Description of rigging work

4.4.5

Unfolding/folding the deflection sheave on the 5 m section This section describes only the unfolding and folding of the deflection sheave on the 5 m section. For folding and unfolding the deflection sheave Folding out / in the deflection sheaves on the 10 m section, on the 10 m section p. 3 - 61.

à

For work with the boom extension you must fold out the deflection sheaves on the rear 5 m section.

Fold the deflection sheave for transport.

Folding out deflection sheave

• Pull the pin (2) out of the bore (3).

• Fold the defection sheave von the strut (1) upwards until the locking positions are aligned with the bore hole (3).

• Fasten the deflection sheave with the pin and secure the pin with a retaining needle.

Folding in deflection sheave

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

• Fold the deflection sheave down as far as possible.

• Insert the pin in the bore hole (3) and secure

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it with a retaining needle.

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Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.4 Description of rigging work

4.4.6

Positioning/removing the hoist cable

G

Risk of accidents due to falling parts!

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

This prevents elements from becoming loose, falling down and injuring people.

22 m boom extension (85 ft boom extension)

27 m boom extension (89 ft boom extension)

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

• For both boom extensions, guide the hoist rope via the deflection sheaves (5), (4), (3) and via the head sheave (2) on the 7 m section.

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

• Attach the hook tackle. The hoist rope can only be reeved once;

20.02.2001

à p. 3 - 65.

Operating instructions lattice extension GMK 4075 2 084 629 en

4 - 21

Boom extension (additional equipment) 4.4 Description of rigging work

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4 - 22

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Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.5 Driving with rigged crane and rigged boom extension

4.5

Driving with rigged crane and rigged boom extension This section describes how you can move the truck crane with installed counterweight and rigged boom extension on site (e.g if, because of lack of space, the boom extension can not be directly installed at the site).

G G 4.5.1

Risk of accidents!

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

Put the load down before you move the truck crane.

Secure the hook block so that it cannot swing.

Risk of overturning!

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

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

20.02.2001

S

Risk of tyre damage!

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

The truck crane may be moved only if tyre pressures are at the prescribed levels; à Operating instructions GMK 4075, Part 1 Carrier – Technical data.

Do not reduce the tyre pressure!

Operating instructions lattice extension GMK 4075 2 084 629 en

4 - 23

Boom extension (additional equipment) 4.5 Driving with rigged crane and rigged boom extension

4.5.2

Boom positions and axle loads

The vehicle may only be moved if certain conditions are met. The boom may have to be moved to a specified position, depending on the installed counterweight.

S

11==

Damage may occur to the axle lines!

Always move the boom to the prescribed position before you move the rigged truck crane. The permitted load on the axle lines will be exceeded if the boom is in a position which deviates from the prescribed position.

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

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

20.02.2001

G

Risk of accidents if SLI is overridden.

Always set the SLI rigging code corresponding to the current rigging mode when you derrick the main boom into the prescribed position. Do not override the SLI; the prescribed positions in the following tables are all within the areas which are permitted according to the Lifting capacity tables.

The truck crane safe load indicator does not function when the SLI is overridden!

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Operating instructions lattice extension GMK 4075

Boom extension (additional equipment) 4.5 Driving with rigged crane and rigged boom extension

22 m boom extension

The following table only applies if the 22 m boom extension is rigged.

Tables for rigged 27 m boom extension; p. 4 - 26.

Tables for rigged lattice extension; p. 3 - 84.

à

H Counterweight in t

9.13)

à

The axle loads specified in the following tables refer to a driving mode with the basic unit and 8 t hook tackle reeved on the lattice extension, hook blocks must be unreeved.

Telescoping Telescope section I/II/III/IV

Main boom angle in °

Lattice extension angle in °

Main boom position1)

0/0/0/0

15

5

0/0/0/0

70

0/0/0/0

Axle load2) in t

Axle load2) x 1000 lbs

at the front

rear

at the front

rear

front

14.5

10.0

32.0

22.0

5

rear

11.5

13.0

25.5

29.0

15

5

front

14.0

11.0

31.0

24.5

0/0/0/0

70

5

rear

11.5

13.5

25.5

30.0

0/0/0/0

15

5

front

13.5

12.5

30.0

27.5

0/0/0/0

70

5

rear

12.5

13.5

27.5

30.0

0/0/0/0

15

5

front

12.0

16.0

26.5

35.5

0/0/0/0

70

5

rear

14.5

13.5

32.0

30.0

10.1

12.1

16.1

1)Boom

position to the rear:

Boom position at the front: 2)Axle

load front:

Axle load rear: 3)The

0° position, boom over truck crane rear edge 180° position, boom over driver's cab Each time on the first and the second axle line Each time on the third and the fourth axle line

counterweight version 9.1 t is additional equipment

20.02.2001

s

Operating instructions lattice extension GMK 4075 2 084 629 en

4 - 25

Boom extension (additional equipment) 4.5 Driving with rigged crane and rigged boom extension

27 m boom extension

The following table only applies if the 27 m boom extension is rigged.

Tables for rigged 22 m boom extension; p. 4 - 25.

Tables for rigged lattice extension; p. 3 - 84.

à

H Counterweight in t

9.13)

à

The axle loads specified in the following tables refer to a driving mode with the basic unit and 8 t hook tackle reeved on the lattice extension, hook blocks must be unreeved.

Telescoping Telescope section I/II/III/IV

Main boom angle in °

Lattice extension angle in °

Main boom position1)

0/0/0/0

15

5

0/0/0/0

70

0/0/0/0

Axle load2) in t

Axle load2) x 1000 lbs

at the front

rear

at the front

rear

front

16.0

8.5

35.5

19.0

5

rear

10.5

14.0

23.5

31.0

15

5

front

15.5

9.5

34.5

21.0

0/0/0/0

70

5

rear

11.0

14.0

24.5

31.0

0/0/0/0

15

5

front

15.0

11.0

33.0

24.5

0/0/0/0

70

5

rear

12.0

14.0

26.5

31.0

0/0/0/0

15

5

front

13.5

14.5

30.0

32.0

0/0/0/0

70

5

rear

14.0

14.0

31.0

31.0

10.1

12.1

16.1

1)Boom

position to the rear:

Boom position at the front: 2)Axle

load front:

4.5.3

180° position, boom over driver's cab Each time on the first and the second axle line

Axle load rear: 3)The

0° position, boom over truck crane rear edge

Each time on the third and the fourth axle line

counterweight version 9.1 t is additional equipment

Driving the rigged crane

à

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Operating instructions lattice extension GMK 4075

20.02.2001

When driving with a rigged boom extension, proceed in the same way as p. 3 - 86. for driving with a rigged lattice extension;

Boom extension (additional equipment) 4.6 Maintenance work

4.6

Maintenance work

4.6.1

Maintenance work M1, monthly

H

For lubricating the pins, use the same grease as stated in the Maintenance manualfor lubricating attach pins and socket pins; à Maintenance manual GMK 4075, Maintenance overview – M1 maintenance plan.

• Lubricate all attach, securing and retaining pins.

20.02.2001

H

The maintenance interval applies to average operation. Also lubricate the pins after high-pressure cleaning and generally at an interval that will prevent them getting dry.

Operating instructions lattice extension GMK 4075 2 084 629 en

4 - 27

Boom extension (additional equipment) 4.6 Maintenance work

20.02.2001

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4 - 28

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Operating instructions lattice extension GMK 4075

5 5

Auxiliary single-sheave boom top (additional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-

1

5.1

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1

5.2

Installing/removing auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . 5 -

3

Installing auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removing the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . 5 -

3 4

Rigging the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

5

5.2.1 5.2.2 5.3

Rigging in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rigging in working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attaching and removing hoist cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Possible reeving methods on the auxiliary single-sheave boom top . . . . . . . .

Lifting limit switch and anemometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55555-

5 6 7 7 8

5.4

Turning loads with the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . 5 -

9

5.5

Driving with rigged crane and installed auxiliary single-sheave boom top . . . . 5 - 14

16.02.2001

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5

Operating instructions lattice extension GMK 4075 2 084 629 en

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Operating instructions lattice extension GMK 4075

Auxiliary single-sheave boom top (additional equipment) 5.1 Identification

5

Auxiliary single-sheave boom top (additional equipment)

5.1

Identification The auxiliary single-sheave boom top is designed for the truck crane it was delivered with. It has the same serial number as the truck crane.

S S

Operate the truck crane only with the auxiliary single-sheave boom top that has the identical serial number.

If you wish to use the auxiliary single-sheave boom top on several GROVE truck cranes, it needs to be adapted to the corresponding crane and marked with all the serial numbers.

The tauxiliary single-sheave boom top should only be adjusted by GROVE Customer Support at the particular location.

20.02.2001

The serial number (1) is on a plaste, in the front on the auxiliary single-sheave boom top.

Operating instructions lattice extension GMK 4075 2 084 629 en

5-1

Auxiliary single-sheave boom top (additional equipment) 5.1 Identification

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5-2

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Operating instructions lattice extension GMK 4075

Auxiliary single-sheave boom top (additional equipment) 5.2 Installing/removing auxiliary single-sheave boom top

5.2

Installing/removing auxiliary single-sheave boom top

G 5.2.1

Risk of accidents if the boom top should fall off!

During installation and removal, always use the proper materials with sufTransport dimensions and weights, p. 2 - 1 ficient load bearing capacities;

à

.

Installing auxiliary single-sheave boom top On the left side of the main boom head there is a holding device.

When installing, the holding device is connected at the front bore holes (1).

• Loosen the retaining pin and remove the pin (1) from the bearing point (2).

• Use an auxiliary crane to couple to the connection eyes (3) on the auxiliary singlesheave boom head and lift it to the left onto the main boom head.

• Align the auxiliary single-sheave boom top so that the bearing point (2) lines up to the front bore holes in the holding device.

• Secure the auxiliary single-sheave boom top to the holding device using a pin (1).

• Secure the pin with a retaining pin.

• Depending on the application, bring the auxiliary single-sheave boom top into transport position or working position;

à Rigging the auxiliary single-sheave boom

20.02.2001

top, p. 5 - 5.

Operating instructions lattice extension GMK 4075 2 084 629 en

5-3

Auxiliary single-sheave boom top (additional equipment) 5.2 Installing/removing auxiliary single-sheave boom top

5.2.2

Removing the auxiliary single-sheave boom top • Attach an auxiliary crane to the connection eyes (1) of the boom top.

In the working position, the auxiliary single-sheave boom top is positioned in front of the main boom head and is fastened with three pins (1).

• Remove the retaining pins and draw all the pins (1) out of the bores and bearing points.

In the working position, the auxiliary single-sheave boom top is positioned to the side of the main boom head and is fastened with two pins (1).

• Remove the retaining pins and draw all the pins (1) out of the bores and bearing points.

• Lift the auxiliary single-sheave boom top from the head of the main boom.

• Insert the two thin pins (1) and (3) into the bearing points (2) and (4) on the auxiliary single-sheave boom top.

• Insert the two pins (5) into the mounting brackets (6) in front on the auxiliary singlesheave boom top.

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• Secure all the pins using retaining pins.

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2 084 629 en

Operating instructions lattice extension GMK 4075

Auxiliary single-sheave boom top (additional equipment) 5.3 Rigging the auxiliary single-sheave boom top

5.3

Rigging the auxiliary single-sheave boom top

5.3.1

Rigging in transport position On the left side of the main boom head there is a holding device.

In transport position, the boom top is connected to the rear bore holes (1) on the holding device

• Remove the retaining pins and take both pins (1) out of the bearing points (2) at the front of the main boom head.

• Insert both pins into the holders (3) and secure them with retaining pins.

• Release the retaining pin and remove the thin pin from the bearing point (4).

• Slew the auxiliary boom top to the side of the main boom head.

• Using the thin pin (1), fasten the auxiliary single-sheave boom top to the bearing point (2).

• Secure the pin with a retaining pin.

20.02.2001

The auxiliary single-sheave boom top is now in transport position.

Operating instructions lattice extension GMK 4075 2 084 629 en

5-5

Auxiliary single-sheave boom top (additional equipment) 5.3 Rigging the auxiliary single-sheave boom top

5.3.2

Rigging in working position On the left side of the main boom head there is a holding device.

In working position, the auxiliary single-sheave boom top is attached to the main boom head at both bore holes.

• Release the retaining pin and remove the thin pin from the bearing point (1).

• Swing the auxiliary single-sheave boom top in front of the main boom head.

• Remove the retaining pin and take out both thick pins (1) from the holders (3).

• Insert both pins into the pivot points (2) at the front of the main boom head and secure them with retaining pins.

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

20.02.2001

The auxiliary single-sheave boom top is now in working position.

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2 084 629 en

Operating instructions lattice extension GMK 4075

Auxiliary single-sheave boom top (additional equipment) 5.3 Rigging the auxiliary single-sheave boom top

5.3.3

Attaching and removing hoist cable • Remove the cable holding rods (1) from the head of the main boom and from the auxiliary single-sheave boom top.

• When reeving, guide the hoist cable over the left head sheave of the main boom.

• Insert the rope holding rod into the appropriate bore holes and secure them with the corresponding retaining pins.

• Fasten the cable end clamp on the hook tackle or the hook block.

Reverse the sequence of operations to remove the hoist cable before slewing the auxiliary boom top into transport position.

5.3.4

Possible reeving methods on the auxiliary single-sheave boom top The hoist cable may only be simply reeved (single drop).

Hook tackle, max. lifting capacity: 8 t maximum load bearing capacity with GMK 4075: for single-reeving 5 t (11,000 lbs)

1-sheave hook block, max. load bearing capacity 20 t

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maximum load bearing capacity with GMK 4075: for simple reeving 5 t (11,000 lbs) for two falls reeving 10 t (22,000 lbs)

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Auxiliary single-sheave boom top (additional equipment) 5.3 Rigging the auxiliary single-sheave boom top

5.3.5

Lifting limit switch and anemometer

In operation

• Pull the plug of the connecting cable from the dummy socket (2).

• Unwind the connecting cable from the holders (3).

• Insert the plug of the connecting cable into the socket (1) on the main boom head.

• Guide the hoist cable through the lifting limit switch weight.

If, additionally, a hook block is reeved on the main boom, connect the lifting limit switch of the main hoist to the socket on the right side of the main boom head; Operating instructions GMK 4075, Part 2 Superstructure – Rigging work.

à

During transport

• Insert the plug of the connecting cable into the dummy socket (2).

• Wind the connecting cable onto the holders (3).

• Plug the short-circuit plug into the socket (1).

Anemometer

• The anemometer is connected to the main boom head as it is for operation with the main boom;

à Operating instructions GMK 4075, Part 2 Su-

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perstructure – Rigging work.

Operating instructions lattice extension GMK 4075

Auxiliary single-sheave boom top (additional equipment) 5.4 Turning loads with the auxiliary single-sheave boom top

5.4

Turning loads with the auxiliary single-sheave boom top When turning loads it is necessary to employ a two-hook operation. The only type of two-hook operation technically possible and protected by the SLI is described in this chapter using the turning of loads as an example.

G G H Prerequisites

Risk of accidents due to overloading.

Lifting a load with two hooks is permissible only if the following instructions and illustrations are observed.

If these instructions are not observed, accidents could occur due to individual parts of the truck crane being overloaded. The SLI then no longer provides protection.

Two-hook operation with the boom extension (additional equipment) is not permitted!

Risk of accidents due to overloading.

The load must always be lifted with the weakest part first (auxiliary singlesheave boom top).

For information on the position and function of the operating instruments required; Operating instructions GMK 4075, Part 2 Description of the truck

à

crane (crane section).

The following description requires that: – the main hoist cable is reeved on the main boom and

Risk of accidents due to overloading.

The reeving on the main boom must be equal to or greater than that on the auxiliary single-sheave boom top.

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

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G

– the auxiliary hoist cable on the auxiliary single-sheave boom top is reeved.

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Auxiliary single-sheave boom top (additional equipment) 5.4 Turning loads with the auxiliary single-sheave boom top

Setting SLI

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

H äå 32 ä

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

• Switch off both hoists.

For this, press down once both the rocker switches main hoist on/off and auxiliary hoist on/off.

Indicator lamps in the rocker switches are dimly illuminated.

When the main hoists are switched off, the main hoist on/off indicator lamp in the Main menu on the Crane control and auxiliary hoist on/off display lights up red.

• Switch on the main hoist.

Additionally, press the main hoist on/off rocker switch down once. The indicator lamp in the rocker switch lights up brightly.

Lamp I for the main hoist lights up in the hoists indicator lamps.

• In the display reeving, enter the quantity of reeved cable of the main hoist

§

cable on the main boom.

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

32

For this, press down once both the rocker switches main hoist on/off and auxiliary hoist on/off.

Indicator lamps in the rocker switches are dimly illuminated.

• Switch on the auxiliary hoist.

Additionally, press the auxiliary hoist on/off rocker switch down once. The indicator lamp in the rocker switch lights up brightly.

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å

• Switch off both hoists.

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Operating instructions lattice extension GMK 4075

Auxiliary single-sheave boom top (additional equipment) 5.4 Turning loads with the auxiliary single-sheave boom top

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

• In the display reeving, enter the number of reeved ropes on the auxiliary

4

hoist rope of the auxiliary single-sheave boom top.

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

ä

Switch on the main hoist.

Additionally, press the main hoist on/off rocker switch down once. The indicator lamp in the rocker switch lights up brightly.

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

11==

• Set the SLI for crane operation with the auxiliary single-sheave boom top, valid for the current rigging mode of the truck crane.

Now the SLI is set for two-hook operation, taking into account the reeving for the auxiliary hoist and the lifting capacity table for the main boom.

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H

The load measurement is taken with the pressure in the derricking cylinder.

The loads detailed in the Lifting capacity table then lessen with respect to the weight of both reeved hook blocks and the weight of the auxiliary singlesheave boom top.

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5 - 11

Auxiliary single-sheave boom top (additional equipment) 5.4 Turning loads with the auxiliary single-sheave boom top

Turning a load

S H H

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

Keep the acceleration force as low as possible during two-hook operation.

Therefore move the load at the lowest possible speed!

As soon as the hoist rope on the main boom is pulled taut, the status display actual load will exhibit slight deviations. However, the differences are on the safe side with regard to SLI shutdown.

With two-hook operation, the SLI code for the main boom remains activated during the entire hoist procedure.

• Lift the load completely off the ground with the auxiliary single-sheave boom top.

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

• Now lift the load with the hook block on the main boom until both slinging

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points are at the same height.

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Operating instructions lattice extension GMK 4075

Auxiliary single-sheave boom top (additional equipment) 5.4 Turning loads with the auxiliary single-sheave boom top

• Reel off hoist rope on the auxiliary single-sheave boom top until the load is hanging from the hook block on the main boom only.

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Turning the load is thus completed.

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Auxiliary single-sheave boom top (additional equipment) 5.5 Driving with rigged crane and installed auxiliary single-sheave boom top

5.5

Driving with rigged crane and installed auxiliary singlesheave boom top

G

Accidents may occur when driving from the crane cab.

Before driving with rigged lattice extension observe all the instructions in the section Driving the truck crane from the crane cabin and set the rigging code described therein for free-standing works.

When driving with rigged lattice extension proceed exactly as prescribed in the section Driving the truck crane from the crane cabin; Operating instructions GMK 4075 – Part 2 Superstructure.

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à

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Operating instructions lattice extension GMK 4075

6 Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1

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Operating instructions lattice extension GMK 4075

Index

6

To avoid making the index unnecessarily long and unclear we have not included every single element from the instrument panel.

These elements, such as rocker switches, warning and indicator lamps as well as status displays are described and named in detail in the overviews of the respective chapters Description of the truck crane in the Operating instructions GMK 4075.

From there, you will be referred to more detailed descriptions of these elements.

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H

Index

Operating instructions lattice extension GMK 4075 2 084 629 en

6-1

Index

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Blank page

6-2

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Operating instructions lattice extension GMK 4075

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Index

A

Auxiliary single-sheave boom top driving with installed auxiliary single-sheave boom top . . . . . . . . . . . . . . . . 5 - 14 mounting / removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 possible reeving methods; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7 rigging in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 in working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Axle loads for driving with rigged boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24 when driving with rigged lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 84

B

Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 safety instructions for truck crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 assembly of boom extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 boom extension slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 CHECK LIST rigging the 22 m/27 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 unrigging the 22 m/27 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9 Driving with an installed boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23 Driving with rigged boom extension axle loads and boom positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27 Rigging work establishing/disconnecting electrical connection . . . . . . . . . . . . . . . . . . . 4 - 18 establishing/disconnecting the hydraulic connection . . . . . . . . . . . . . . . . 4 - 15 installing/removing 5 m sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13 positioning/removing the hoist cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21 unfolding/folding the deflection sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20

E

Electrical system at the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18 on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 58

H

Hoist rope possible reeving methods on the auxiliary single-sheave boom top . . . . . . . 5 - 7 possible reeving methods on the boom extension . . . . . . . . . . . . . . . . . . . . . 3 - 65 possible reeving methods on the lattice extension . . . . . . . . . . . . . . . . . . . . . 3 - 65 Hydraulic system on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 60

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Index

L

M

6-4

Identification of the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . of the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . of the two-stage swing-away lattice extension . . . . . . . . . . . . . . . . . . . . . . . . .

Important information about these operating instructions . . . . . . . . . . . . . . . . . .

5-1 4-1 3-5 1-1

Lattice extension assembly of the lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7 centres of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 CHECK LIST installing the two-stage swing-away lattice extension . . . . . . . . . . . . . . . 3 - 10 removing two-stage swing-away lattice extension . . . . . . . . . . . . . . . . . . 3 - 12 rigging the 10 m swing-away lattice extension . . . . . . . . . . . . . . . . . . . . . 3 - 14 rigging the 17 m two-stage swing-away lattice extension . . . . . . . . . . . . 3 - 23 unrigging the 10 m swing-away lattice extension . . . . . . . . . . . . . . . . . . . 3 - 18 unrigging the 17 m two-stage swing-away lattice extension . . . . . . . . . . 3 - 27 driving with rigged lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 83 axle loads and boom positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 84 maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 93 rigging work checking the transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35 connections on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 53 connections on the main boom head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 49 connections with folded lattice extension in front area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 43 in middle area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 45 in rear area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 47 establishing/disconnecting electrical connection . . . . . . . . . . . . . . . . . . . 3 - 58 establishing/disconnecting the hydraulic connection . . . . . . . . . . . . . . . . 3 - 60 folding deflection sheave out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 61 folding the run-up rail out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 41 hose drum hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 38 installing the two-stage swing-away lattice extension . . . . . . . . . . . . . . . 4 - 14 positioning/removing the hoist cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 64 swinging the 7 m section in front of the 10 m section . . . . . . . . . . . . . . . 3 - 57 swinging the lattice extension onto the main boom . . . . . . . . . . . . . . . . . 3 - 55 turning the lattice extension in front of the main boom . . . . . . . . . . . . . . 3 - 56

Maintenance work on the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Malfunctions when working with lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . when working with the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measurement in US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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I

Index

S

SLI shutdown during. during work with the boom extension . . . . . . . . . . . . . . . 3 - 75 switching off when working with the lattice extension . . . . . . . . . . . . . . . . . 3 - 75

Transport condition of the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35 Transport dimensions and weights in metric units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 in US units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Turning loads with the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9 with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77

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