Grove GMK7450 Operating Instructions Mega Wing Lift (MWL) Manual - PDF DOWNLOAD

Operating instructions Mega Wing Lift (MWL) Serial number

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Important note

Duplications of any kind and excerpts from this document are not subject to the revision service.

Original documents of Deutsche GROVE GmbH are marked with the blue serial number of the truck crane on the cover sheet.

© Copyright reserved by Deutsche GROVE GmbH The passing on or duplication of this document as well as the utilization and disclosure of its contents are prohibited unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility model are reserved.

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MWL Operating instructions GMK 7450

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Duplications and printouts of data carriers on which Deutsche GROVE GmbH has delivered this document are also not subject to the revision service.

The following chapters are contained in these operating instructions: 1 Important information 2 Transport dimensions and weights 3 Scope of delivery and function 4 Additional operating and display elements 5 MWL – Rigging and unrigging 6 Operation with the main boom and the MWL 7 Operation with boom extension and MWL 8 Operation with the luffing jib and the MWL 9 Operation with heavy load lattice extension and MWL 10 Malfunctions during operation with the MWL 11 Maintenance work on the MWL

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12 Index

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MWL Operating instructions GMK 7450

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1 1

Important information

1.1

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

1

1.2

Supplementary instructions to the operating instructions for the GMK 7450 . . 1 -

2

Addition to the driving mode table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Addition to the Telescoping emergency program submenu . . . . . . . . . . . . . . . 1 Addition to applications engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

2 2 3

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

5

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

5

1.4

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

7

1.5

Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

9

1.6

Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11

1.7

Safety instructions for truck crane work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13

1.2.1 1.2.2 1.2.3 1.3

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1.3.1

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MWL Operating instructions GMK 7450

Important information 1.1 About these operating instructions

1 1.1

Important information

About these operating instructions

Abbreviations used

These operating instructions describe a load increasing system, which is available as additional equipment. The system is called Mega Wing Lift and is abbreviated in these operating instructions to MWL (Mega Wing Lift).

Validity of these operating instructions

These operating instructions only apply to original parts supplied by Deutsche GROVE GmbH and describe the operation of the MWL. In addition, operation of the truck crane is also subject to all the specifications in the Operating instructions accompanying the GMK 7450 for which the MWL was manufactured.

For the operation of the truck crane with the lattice extensions described in these operating instructions, but without the MWL, the GMK 7450 Lattice extension operating instructions apply.

Prerequisites for assembly and operation

The MWL described in these operating instructions may only be operated together with a GROVE GMK 7450 truck crane whose serial number is identical with the serial number that is marked on the MWL.

Safety instructions

The operation of GMK 7450 with the MWL described in these operating instructions is subject to: – the basic safety instructions to be found in the subsequent section Basic safety instructions and – the safety instructions contained in the operating instructions supplied for the GMK 7450.

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References to other operating instructions

Cross references to other operating or maintenance instructions are shown in the following forms: GMK 7450 operating instructions, Part 1 Superstructure – Rigging work The number for the chapter on Rigging work is found at the front, on the second page of the operating instructions specified. or GMK 7450 operating instructions – Safe load indicator The corresponding page number can be found in the index, under the entry for Safe load indicator.

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1-1

Important information 1.2 Supplementary instructions to the operating instructions for the GMK 7450

1.2

Supplementary instructions to the operating instructions for the GMK 7450

1.2.1

Addition to the driving mode table For truck cranes that are supplied with MWL, you must not only observe the specifications in the accompanying GMK 7450 operating instructions, but also the following points in addition, so that the axle load of 12 t (26 400 lbs) is not exceeded during on-road driving.

Rigging mode

Driving mode

1.2.2

1

2

3

4

5

6

7

The MWL has been completely removed

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Both side head sheaves have been removed

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The removable rests for the rear pendant links have been removed from the basic section of the main boom

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The rope grab is fastened on the main boom, either in the front holder or in the rear holder

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Addition to the Telescoping emergency program submenu When the MWL is rigged and the Telescoping emergency program is switched on, the winches of the MWL do not follow automatically when telescoping. For this reason, before using the Telescoping emergency program, please note the information given in the Malfunctions during operation with the MWL chapter; Telescoping in the emergency program with a rigged MWL, p. 10 - 22.

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Important information 1.2 Supplementary instructions to the operating instructions for the GMK 7450

1.2.3 Thresholds for the use of the main hoist

Addition to applications engineering Use of the MWL makes it possible to lift heavier loads with longer boom lengths. This requires a corresponding increase in the more falls of the hoist rope to be reeved and more hoist rope is needed than for operation without MWL. This means that when using the main hoist (hoist rope length 460 m (1 509 ft)), you cannot reach the ground with the hook block or with the load at certain threshold ranges, with the boom in its steepest position.

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

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

Length of the main boom

Reeving

Minimum hook height with main hoist

16.03 m (52.6 ft)

26

3 m (10 ft)

32

6 m (20 ft)

18

1 m (3 ft)

22

4.5 m (15 ft)

28

3 m (10 ft)

25.68 m (84.3 ft)

18

5.5 m (18 ft)

22

10.5 m (34 ft)

30.50 m (100.1 ft)

15

6 m (20 ft)

18

11 m (35 ft)

11

1 m (3 ft)

13

7 m (23 ft)

16

13 m (43 ft)

40.15 m (131.7 ft)

12

9 m (30 ft)

14

14 m (46 ft)

44.98 m (147.6 ft)

10

8 m (26 ft)

13

17 m (56 ft)

8

6 m (10 ft)

9

9 m (30 ft)

10

13 m (43 ft)

54.63 m (179.2 ft)

8

1 m (3 ft)

9

8 m (26 ft)

60.00 m (196.6 ft)

7

7m (23 ft)

20.85 m (68.4 ft)

35.33 m (115.9 ft)

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49.80 m (163.4 ft)

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1-3

Important information 1.2 Supplementary instructions to the operating instructions for the GMK 7450

Three-part rope holding rod

For operation with MWL, the accompanying three-part rope holding rod must be installed.

A continuous, solid rope holding rod is a standard fitting in the main boom head (2).

When the side head sheaves (1) are installed, you cannot pull the standard rope holding rod (1) out any more.

Therefore, replace the standard rope holding rod (2) with the accompanying three-part rope holding rod (3) before use; Installing/removing the three-part rope holding rod, p. 6 - 4.

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Sheaves for operation with lattice extension

A deflection sheave with support roller must be installed on the foot section of the lattice extension for operation with MWL and boom extension or with MWL and luffing jib.

If the deflection sheave with support roller (1) was not already installed when the foot section was delivered, it has been delivered with the MWL and must be fitted in the place of the deflection sheave with the small safety roller Installing the deflection (2) before first use; sheave with support roller, p. 7 - 5.

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Important information 1.3 Basic safety instructions

1.3

Basic safety instructions

1.3.1

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

G S B O H s

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

This symbol indicates dangers which could put objects at risk, e.g. damage to the truck crane, the load or the environment.

This symbol alerts you to situations where there is a risk 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 hanMaintenance mandling substances that pose a risk to the environment; ual, Chapter Safety and environmental protection.

à

The vertical line to the left of the warning text indicates the following: 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 regarding truck crane operation.

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

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Horizontal lines always indicate the start or the end of an example. The text used for examples is in a different font.

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Important information 1.3 Basic safety instructions

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MWL Operating instructions GMK 7450

Important information 1.4 Intended use

1.4

Intended use The truck crane GMK 7450 is constructed in accordance with the latest technology 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 7450 may only be used when in excellent working condition and for its intended purpose, and with due attention to safe operation and any possible hazards.

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

The GMK 7450 truck crane may only be operated at temperatures of between –25 to +40 °C (–13 to +104 °F) unless fitted with the appropriate special equipment.

The GMK 7450 truck crane may only be used to vertically lift loads in the authorized rigging modes using a hook block that is reeved to the hoist rope.

The weight and centre of gravity of the loads must be known. Any other use of the crane is not considered to represent intended use.

The manufacturer is not liable for damage resulting from the improper or unauthorized use of the truck crane GMK 7450. The user shall take full responsibility for any such use.

Intended use also entails – Following the complete crane documentation consisting of the operating instructions, the lifting capacity table, the outrigger pressure table and the safety manual – Adhering to the inspection and maintenance requirements specified in the maintenance manual.

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Important information 1.4 Intended 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 mechanism – 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 indicator 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 – Use of equipment that is not authorized for use with the crane – Transporting people in any way with the lifting tackle, upon the load, or in the crane cab while driving – Carrying passengers outside the driver's cab – Loading and unloading work, i.e. continuous operation without a sufficiently long break – Usage for any kind of sport or recreation event, especially for bungee jumping

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– Operation of the truck crane with erected and non-braced MWL with rigged lattice extension.

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Important information 1.5 Organisational measures

1.5

Organisational 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 capacity table, observe all general, statutory and otherwise applicable regulations concerning accident prevention and environmental protection. You must have read and understood these and must comply with them when working.

These could include: – How to deal with hazardous materials – Wearing personal protective equipment – Traffic regulations – 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. Instruct your employees (e.g. banksmen, slingers, rigging personnel) accordingly.

Ensure that the maintenance personnel possess the necessary expertise 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.

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Important information 1.5 Organisational measures

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

Note the operational organization on the site. Report your arrival to site management. Ask for the employee authorized to instruct you.

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 persons responsible.

Do not make any changes to the programmable control systems (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 prior permission. To avoid any damage, especially to electronic parts, there are certain steps you must take before doing any welding work. You should therefore 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 fulfil 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.

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MWL Operating instructions GMK 7450

Important information 1.6 Personnel qualifications

1.6

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 fulfil 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 to 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 personnel with special knowledge and experience 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 conducts general and type-related crane operator courses and technical courses.

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Important information 1.6 Personnel qualifications

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Important information 1.7 Safety instructions for truck crane work

1.7

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 checklists 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 them, 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 unauthorized people in the vicinity of or on the truck crane when rigging or during crane work. Secure the danger zone using cordons and mark the zone as such.

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Important information 1.7 Safety instructions for truck crane work

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 vertically 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.

Before turning the superstructure, support the truck crane with the outrigger span required for the currently rigged counterweight.

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. Both the truck crane and the equipment must have the same serial number.

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 live electrical cables as well 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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2 Transport dimensions and weights

2.1

Mega Wing Lift (MWL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1

2.2

Add-on parts for the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1

2.3

Add-on parts for lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

2

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Transport dimensions and weights 2.1 Mega Wing Lift (MWL)

2 2.1

2.2

Transport dimensions and weights

Mega Wing Lift (MWL) Description

Length x width x height (m) (ft)

Weight (kg) (lbs)

MWL complete

11.15 x 3.00 x 1.70 36.60 x 9.85 x 5.60

10 270 22 640

Add-on parts for the truck crane Description

Length x width x height in m (ft)

Weight in kg (lbs)

Side head sheave each, complete

1.20 x 0.90 x 0.30 (4.0 x 3.0 x 1.0)

170.0 (375.0)

Rests at rear for the rear pendant links, each

0.50 x 0.15 x 0.45 (1.65 x 0.50 x 1.45)

10.5 (23.5)

Rests at centre for the rear pendant links, each

0.45 x 0.30 x 0.20 (1.45 x 1.00 x 0.65)

8.0 (17.7)

Rests at front for the rear pendant links, each

0.40 x 0.10 x 0.45 (1.30 x 0.35 x 1.45)

11.5 (25.5)

Rope grab

1.55 x 1.75 x 0.20 (5.10 x 5.75 x 0.65)

43.0 (95.0)

1.07 (0.3 + 0.47 + 0.3) x ø 0.02 (3.5 (1.00 + 1.55 + 1.00)) x ø 0.07

2.6 (5.7)

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Rope holding rod (three-part)

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2-1

Transport dimensions and weights 2.3 Add-on parts for lattice extension

2.3

Add-on parts for lattice extension Description

Length x width x height in m (ft)

Weight in kg (lbs)

Deflection sheave with retaining sheet 1)

0.80 x 0.60 x 0.30 (2.65 x 2.00 x 1.00)

58 (128)

Folding support roller complete with pins and retaining pins (for foot section of lattice extension)

0.70 x 0.60 x 0.30 (2.30 x 2.00 x 1.00)

50 (111)

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1) Installed on the foot section for the lattice extension. Depending on the serial number, this foot section may be delivered with this deflection sheave directly attached.

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3 3

Scope of delivery and function

3.1

Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

1

Add-on parts on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MWL and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

2 3

Function of the MWL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

4

3.1.1 3.1.2

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3.2

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Scope of delivery and function 3.1 Scope of delivery

3

Scope of delivery and function This chapter shows the parts that are delivered when MWL is supplied as additional equipment and provides an overview of MWL’s function.

3.1

Scope of delivery If the truck crane is delivered with an MWL, various different parts will be supplied. There are: – Several parts that are built onto the main boom; main boom, p. 3 - 2

à Add-on parts on the

– Several parts that are supplied together with the MWL as individual comMWL and components, p. 3 - 3. ponents;

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3-1

Scope of delivery and function 3.1 Scope of delivery

3.1.1

Add-on parts on the main boom

1 Holder for rope grab 2 Mountings for holding frames 3 Holders for the rear pendant link rests 1) 4 Pivot point for raising cylinder 1) 5 Axles and holder for side head sheaves 1) 6 Additional head sheave 7 Locking point for MWL fitted on both sides

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1)

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Scope of delivery and function 3.1 Scope of delivery

3.1.2

MWL and components

1 Special slinging tackle 2 Hand-held control MWL up to serial no. 9019 (with dark grey user interface) or hand-held control from serial no. 9020 3 Three-part rope holding rod 4 Pin rigging tool 5 MWL complete 6 Side head sheaves (2x) 7 Rests for the rear pendant links

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8 MWL operation support roller (only for boom extension or luffing jib) 9 Deflection sheave with retaining sheet (may be installed on lattice extension foot section when delivered)

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Scope of delivery and function 3.2 Function of the MWL

Function of the MWL

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3.2

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Scope of delivery and function 3.2 Function of the MWL

The Mega Wing Lift is a steel construction consisting of the holding frame (4), the rear pendant links (3) and the raising frame (10).

There are two gantry masts with winches located on the raising frame: – The gantry mast on the right (13) with the winch on the right (1).

– The gantry mast on the left (7) with the winch on the left (2).

The holding frame (4), the raising frame (10) and the two raising cylinders (5, 6) are bolted to the basic section of the main boom.

The two raising cylinders, together with the gantry masts and winches, raise the raising frame (10). The holding frame (4) stays on the basic section of the main boom and acts as a supporting point for the rear pendant links.

There is a guy rope on each winch. The guy rope on the left (8) is fastened with a rope loop to the side sheave (9) on the left of the main boom head and the guy rope on the right (12) is fastened in the same way on the right side.

The individual gantry masts can be folded out to the side and back in using the two tilt cylinders (11).

When telescoping, the winches are automatically moved freely.

If the main boom has been telescoped and the telescopic sections are locked, the gantry masts are folded out and the bracing procedure can take place. This involves both winches being wound up until the guy ropes are loaded with the required force (the force in the guy ropes is recorded by load cells).

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The stress thus created in the boom system compensates for the force that arises in the boom when a load is lifted. In this way, the whole boom is balanced and the load bearing capacity increased.

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Scope of delivery and function 3.2 Function of the MWL

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4 4

Additional operating and display elements

4.1

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

1

Crane control display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 On the SLI display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 On the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

1 7 8

4.1.1 4.1.2 4.1.3 4.2

In the main menu and in the luffing jib submenu. . . . . . . . . . . . . . . . . . . . . . . .

In the submenu Operation MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

In the submenu Rigging MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On the SLI display – Enter rigging mode submenu . . . . . . . . . . . . . . . . . . . . . .

On the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

Function of the additional operating and display elements . . . . . . . . . . . . . . . . . 4 - 11

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11 11 20 25 27

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

4 4.1

Additional operating and display elements

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

4.1.1

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

In the main menu

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

1 Submenu for Operation – MWL

à p. 4 - 2 Function of the button; à p. 4 - 11

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Submenu overview;

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

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Submenu for Operation – MWL

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

1.1 Lock winches 1.2 Unlock winches 1.3 Display for left-hand winch locking 1.4 Display for left-hand current rope force 1.5 Display for right-hand winch locking 1.6 Display for right-hand current rope force 2.1 Bracing angle display 2.2 Current main boom angle display 2.3 Bracing angle set value display 3.1 Brace the boom system 3.2 Bracing status display 4 Emergency program display 5.1 Fold in left-hand gantry mast 5.2 Fold out left-hand gantry mast 5.3 Display for left-hand gantry mast 6 Display MWL 5°/90° 7.1 Fold in right-hand gantry mast 7.2 Fold out right-hand gantry mast 7.3 Display for right-hand gantry mast 8 Submenu for Rigging -MWL Submenu overview Function of the button 9 Derricking gear display 10.1 Telescoping mechanism display 10.2 Locking status display 10.3 Display for telescoping cylinder in foot section 10.4 Directional indicator for teleautomation 10.5 Enter set value of teleautomation 11 Luffing jib submenu

à p. 4 - 12 à p. 4 - 12 à p. 4 - 13 à p. 4 - 11 à p. 4 - 13 à p. 4 - 11 à p. 4 - 13 à p. 4 - 13 à p. 4 - 13 à p. 4 - 14 à p. 4 - 14 à p. 4 - 18 à p. 4 - 16 à p. 4 - 15 à p. 4 - 17 à p. 4 - 17 à p. 4 - 16 à p. 4 - 15 à p. 4 - 17 à p. 4 - 4 à p. 4 - 14 à p. 4 - 18 à p. 4 - 19 à p. 4 - 18 à p. 4 - 19 à p. 4 - 19 à p. 4 - 19 à p. 4 - 19

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

Submenu for Rigging – MWL

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!

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

1.1 Lock left-hand winch 1.2 Unlock left-hand winch 1.3 Display for left-hand winch locking 1.4 Display for left-hand current rope force 2.1 Lock right-hand winch 2.2 Unlock right-hand winch 2.3 Display for right-hand winch locking 2.4 Display for right-hand current rope force 3.1 Wind left-hand winch 3.2 Unwind left-hand winch 4 Emergency program display 5.1 Wind right-hand winch 5.2 Unwind right-hand winch 6 Display for left-hand gantry mast 7 Display for right-hand gantry mast 8 Submenu for Operation – MWL Submenu overview Function of the button 9.1 MWL – set down 9.2 MWL – raise 9.3 Display MWL 5°/90°

à p. 4 - 22 à p. 4 - 21 à p. 4 - 22 à p. 4 - 20 à p. 4 - 22 à p. 4 - 21 à p. 4 - 22 à p. 4 - 20 à p. 4 - 21 à p. 4 - 20 à p. 4 - 18 à p. 4 - 20 à p. 4 - 20 à p. 4 - 24 à p. 4 - 24 à p. 4 - 2 à p. 4 - 24 à p. 4 - 23 à p. 4 - 23 à p. 4 - 24

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

In the luffing jib submenu

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

1 Submenu for Operation – MWL

à p. 4 - 2 Function of the button; à p. 4 - 11

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Submenu overview;

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

4.1.2

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

à p. 4 - 25

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

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

4.1.3

On the hand-held control

Hand-held control

The hand-held control shown below is supplied with cranes with a serial no. starting with to 9020.

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

1

Crane engine operating panel

à GMK 7450 operating instructions – Crane engine operating panel

Pre-selection button for emergency operation

3

Two-hand operating panel

4

Pre-selection button for rigging

à GMK 7450 operating instructions –

Pre-selection button for emergency operation

à p. 4 - 31 à p. 4 - 28

5 to 7 No function

H 4-8

Required connections for the different movements

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2

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

Hand-held control for the MWL

The hand-held control shown below is supplied with cranes with a serial no. of up to 9019.

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

1

Crane engine operating panel

à GMK 7450 operating instructions – Crane engine operating panel

2

Pre-selection button for emergency operation

3

Two-hand operating panel

4

Pre-selection button for rigging

à GMK 7450 operating instructions –

Pre-selection button for emergency operation

à p. 4 - 31 à p. 4 - 28

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5 to 7 No function

H

Required connections for the different movements

MWL Operating instructions GMK 7450

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à p. 4 - 27

4-9

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

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

4.2

Function of the additional operating and display elements

H 4.2.1

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

In the main menu and in the luffing jib submenu

1

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

The button is not active.

Symbol is black:

The button is active.

After the button is pressed, the Operation – MWL submenu is opened.

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

4.2.2

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

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

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

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

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

F

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

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

The button is not active.

Symbol is black:

The button is active.

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

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

G

Unlock winches his is used for unlocking the left-hand winch and the right-hand winch.

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

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

Unlocking not enabled.

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

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

Symbol is black:

Unlocking enabled.

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

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

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

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

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

a e e c

b f f d

– The Locked position is shown in green

S

Bracing angle display

– The Unlocked position is shown in red

– Intermediate positions are shown in yellow

– A defective status is detected by the crane control and is shown by a violet symbol (!) (e.g. both proximity switches report at the same time).

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

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

Symbol is grey:

The main boom is not located at the bracing angle.

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

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

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

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

T

Brace the boom system Used for bracing the boom system.

The button is only active when the following prerequisites are met: – – – – – –

The MWL has been raised to 90°.

The gantry masts have been folded out.

The main boom is located at the bracing angle.

The telescopic sections are locked.

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

The SLI code for operation with the MWL has been entered.

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

Symbol is black:

The button is active.

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

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

R

Bracing status display Indicates whether the boom system is braced or not: Symbol is green: The boom system has been braced, the bracing procedure has been completed.

Symbol is grey:

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

k

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

U

Submenu for Rigging – MWL When the button next to the symbol is pressed, the display switches to the Rigging – MWL submenu; In the submenu Rigging MWL, p. 4 - 20.

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

JK

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

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

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

JK

Symbol is light grey: The buttons are not active.

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

JK

Symbol is black:

The button is active.

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

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

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

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

HI

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

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

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

JK

Symbol is light grey: The buttons are not active.

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

HI

Symbol is black:

The button is active.

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

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

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

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

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

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

P L N l

Q M O n

– The Folded out position is shown in green.

– Intermediate positions are shown in yellow.

– The Folded in position is shown in green.

– A defective status is detected by the crane control and is shown by a violet symbol (!) (e.g. both proximity switches report at the same time).

Display MWL 5°/90° Displays the various positions that are recorded when raising and setting down the MWL.

X p q m

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

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

– The position MWL placed under 5° is displayed in green.

A defective status is detected by the crane control and is shown by a purple symbol (!) (e.g. both proximity switches report at the same time).

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

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

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

– The telescoping cylinder is locked.

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

Red:

One or more of the prerequisites has not been met.

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

When the MWL is rigged, you also have to observe additional points when Operation with emergency program telescoping in the emergency program; switched on, p. 10 - 19.

à

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

off

8 9

Lowering Raising

Red:

blocked

Green:

released

Red:

blocked

Green:

released

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

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

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

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

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

off

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

8 9

Extending Retracting

Red:

blocked

Green:

released

Red:

blocked

Green:

released

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

xx.x t

+xx.x°

+xx.x°

1 Display for telescoping cylinder in foot section 2 Directional indicator for teleautomation 3 Enter set value of teleautomation

0

Luffing jib submenu For switching to the luffing jib submenu. The button next to the symbol is only active when a luffing jib is connected electrically. The colour of the symbol indicates whether the button is active: Symbol is light grey: The button is not active.

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Symbol is black:

The button is active.

After the button is pressed, the luffing jib submenu is opened.

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

When the luffing jib is switched on, the Bracing angle display will also appear p. 8 - 2. in the symbol;

à

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

4.2.3

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

The display switches to the Operation – MWL submenu.

– In the Operation – MWL submenu, press the button next to the symbol.

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

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

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

gh

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

The winches can be wound in independently of one another.

The buttons next to the symbols are only active when the winch in question has been unlocked. The colour of the symbol indicates whether the button is active: Symbol is light grey: The button is not active.

The button is active.

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

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Symbol is black:

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

ij

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

The winches can be unwound independently of one another.

The buttons next to the symbols are only active when the winch in question has been unlocked. The colour of the symbol indicates whether the button is active: Symbol is light grey: The buttons are not active.

Symbol is black:

ef

The button is active.

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

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

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

The colour of the symbol indicates whether unlocking is enabled: Symbol is light grey: Unlocking not enabled.

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

ef

Symbol is black:

Unlocking enabled.

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

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

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

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

ab

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

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

Symbol is black:

The button is active.

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

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

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

b f f d

– The Locked position is shown in green.

– The Unlocked position is shown in red.

– Intermediate positions are shown in yellow.

– A defective status is detected by the crane control and is shown by a violet symbol (!) (e.g. both proximity switches report at the same time).

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

Z

MWL – raising This is used for raising the MWL to the 90° position. The colour of the symbol indicates whether the button is active: Symbol is light grey: The button is not active.

Symbol is black:

The button is active.

When the button is pressed, the MWL will be raised.

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

The end position Raised 90° is shown by the display MWL 5°/90°.

Y

MWL – setting down Used for setting the MWL down on the main boom basic section. The button is only active if both gantry masts have been folded in and the main boom is at an angle less than 5°. The colour of the symbol indicates whether the button is active: The colour of the symbol indicates whether the button is active: Symbol is light grey:

The button is not active.

Symbol is black:

The button is active.

After the button is pressed, the MWL will be set down.

The procedure continues until the 5° position is reached.

Control symbol

The symbol appears when the setting down procedure is interrupted at the 5° position.

It prompts you to check whether the left-hand deflection sheave on the raising frame is in the Transport position.

Ö

After pressing the Confirm entry button ( ), the symbol Set down MWL will be shown in black again, and the button under the symbol becomes available again.

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

Display MWL 5°/90° Displays the various positions that are recorded when raising and setting down the MWL.

X p q m

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

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

– The position MWL placed under 5° is displayed in green.

A defective status is detected by the crane control and is shown by a violet symbol (!) (e.g. both proximity switches report at the same time).

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

Q M O n

– The Folded out position is shown in green.

V

Submenu for Operation – MWL

– Intermediate positions are shown in yellow.

– The Folded in position is shown in green.

– A defective status is detected by the crane control and is shown by a violet symbol (!) (e.g. both proximity switches report at the same time).

When the button next to the symbol is pressed, the display switches to the Operation-MWL submenu; In the submenu Operation MWL, p. 4 - 11.

à

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

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

When the MWL is rigged, you also have to observe additional points when Operation with emergency program telescoping in the emergency program; switched on, p. 10 - 19.

à

4.2.4

On the SLI display – Enter rigging mode submenu

R

Input – MWL The symbol is only displayed when the SLI on the truck crane is equipped with a program version containing operation with MWL. The button next to the displayed symbol is always active.

If the symbol is not displayed, then the truck crane is not equipped for operation with MWL. When the button next to the Input – MWL symbol is pressed, operation with MWL will be selected on the SLI if it is permissible for the rigging mode displayed: – If operation with MWL is not permissible, nothing will change when the button is pressed, and the symbol will still be shaded grey.

– If operation with MWL is permissible, the symbol will be shaded green and the Current boom system display will show the selected rigging mode, e.g. the main boom (1) with MWL.

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

à

p. 6 - 11 Operation with main boom; p. 7 - 11 Operation with boom extension; p. 8 - 1 Operation with luffing jib; Operation with heavy load lattice extension;

à

à

à p. 9 - 1.

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

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

4.2.5 Connections for hand-held control

On the hand-held control The only sockets which are designed for connecting the hand-held control are those described in this section. If you connect the hand-held control to a different socket, none of the buttons will work.

The connections to the hand-held controls differ only in terms of the form of the sockets.

Sockets (2) and (4) show the connections to the hand-held control MWL for cranes up to serial no. 9019; sockets (1) and (3) show the connections to the hand-held control for cranes of serial no. 9020 and above.

The following are provided for connecting the hand-held control and the MWL hand-held control: – Sockets (1) or (2) on the left-hand derricking cylinder and – Sockets (3) or (4) on the right-hand derricking cylinder

Only certain operations can be carried out from each socket.

Socket

Released operations

1 or 2

On the lefthand derricking cylinder

– – – –

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

3 or 4

On the righthand derricking cylinder

– – – –

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

To connect the hand-held control to the sockets; hand-held control, p. 5 - 41.

à Connecting/removing the

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

Pre-selection button for rigging

7

For pre-selection of the function which is to be manipulated for rigging the MWL. There are fifteen pre-selection buttons with indicator lamps. Seven of these pre-selection buttons have functions for the MWL. Press the corresponding button to pre-select. Only the buttons which are relevant to the MWL will be described below.

Pre-selection button for folding in gantry mast For pre-selecting the function Fold in gantry mast. The only gantry mast preselected will always be the one on the side where the hand-held control has also been connected.

When the button is pressed, the red LED in the button will light up and the buttons on the two-hand operating panel will be set to this function; Two-hand operating panel, p. 4 - 31.

à

?

Pre-selection button for locking/unlocking winch For pre-selecting the function for Lock/unlock winch. The only winch pre-selected will always be the one on the side where the hand-held control has also been connected.

When the button is pressed, the red LED in the button will light up and the buttons on the two-hand operating panel will be set to this function; Two-hand operating panel, p. 4 - 31.

à

=

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

When the button is pressed, the red LED in the button will light up and the buttons on the two-hand operating panel will be set to this function; Two-hand operating panel, p. 4 - 31.

à

9

Pre-selection button for MWL – raising/setting down For pre-selecting the functions MWL – raising/setting down. The function operates regardless of which side the hand-held control is connected on.

When the button is pressed, the red LED in the button will light up and the buttons on the two-hand operating panel will be set to this function; Two-hand operating panel, p. 4 - 31.

à

No function The other buttons here have no function.

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>+:

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

3 >=

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

4

Left-hand red LED lit up:

Left-hand winch in end position Unlocked

Right-hand red LED lit up:

Right-hand winch in end position Unlocked

5

Left-hand green LED lit up:

Left-hand winch in end position Locked

2 2 6

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

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

Both LEDs flashing simultaneously:

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

– When the red LED in the pre-selection button for Fold in gantry mast is lit up, the indicator lamp will show the current position of the pre-selected gantry mast (gantry mast right or left):

4

Left-hand red LED lit up:

Gantry mast left in end position Folded out

Right-hand red LED lit up:

Gantry mast right in end position Folded out

5

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

2 2

Right-hand green LED lit up: Gantry mast right in end position Folded in Both LEDs flashing:

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

Both LEDs flashing simultaneously:

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

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

8 5 2 4

– When the red LED in the pre-selection button Raise/set down MWL lights up, the indicator lamp monitors the position of the MWL: Green diode lit up:

MWL has been raised to 90°.

Both LEDs flashing in rotation:

MWL is between 5° and 90°.

Red diode lit up:

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

It prompts you to check whether the lefthand deflection sheave is in the Transport position on the raising frame.

After pressing the F1 button ( @ ), the movement Set down MWL will be enabled again.

4 2

MWL is under 5°.

Both LEDs flashing simultaneously:

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

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

The red diode in the button lights up when the procedure to set down the MWL in the 5° position was interrupted and the red diode is flashing in the Locking status indicator lamp ( 4 ).

This confirms that the left-hand deflection sheave on the raising frame is in the Transport position.

After pressing the F1 button, the diode in the F1 button goes out and the procedure to set down the MWL is enabled.

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A

Red diode lit up:

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MWL Operating instructions GMK 7450

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

Two-hand operating panel

The buttons in the two-hand operating panel are used to carry out the preselected function or move the pre-selected power unit. It is always necessary to press two buttons to do this: – A direction button and also – A movement button.

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

Movement button You then press the movement button Right/up (1) or the movement button Left/down (2) to start the pre-selected movement.

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

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

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

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

Possible movements for the rigging pre-selection buttons MWL Button combination

Lock/unlock winch

Wind/unwind winch

Folding in gantry mast

MWL – raising / setting down

>

<

6

8

No function

No function

No function

Lock winch (right-hand or left-hand winch depending on connection)

Unlock winch (right-hand or left-hand winch depending on connection)

Wind winch

No function

(right-hand or left-hand winch depending on connection)

Fold in gantry mast (right-hand or left-hand depending on connection)

Raise gantry mast

Unwind winch No function

Set down gantry mast

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(right-hand or left-hand winch depending on connection)

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MWL Operating instructions GMK 7450

5 5

MWL – Rigging and unrigging

5.1

Identification and slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1 3

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

5

5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7 5.3.8 5.3.9 5.3.10 5.3.11 5.3.12 5.3.13 5.3.14 5.3.15 5.3.16 5.3.17 5.3.18 5.3.19 5.3.20 5.3.21 5.3.22 5.3.23 5.4

Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 Preparing the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing/removing the rests for the rear pendant links. . . . . . . . . . . . . . . . . . .

Moving the rope grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing/removing the lateral head sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the rigging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MWL – Slinging and fastening the guide ropes . . . . . . . . . . . . . . . . . . . . . . . . .

Push the supports in/out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Establishing/breaking the hydraulic connection between the MWL and the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MWL – lowering/raising on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting/disconnecting the holding frame and main boom . . . . . . . . . . . . .

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

Establishing/disconnecting the electrical connection . . . . . . . . . . . . . . . . . . . . .

Connecting/removing the hand-held control. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting/disconnecting the raising cylinder and main boom . . . . . . . . . . . .

Moving the turnbuckles for the rear pendant links into the position Operation/Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Establishing/releasing the connection between the gantry masts and the holding frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving the deflection sheaves into the position Operation/Transport. . . . . . .

Running the hoist rope to the main boom head . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning/removing the hoist ropes on/from the deflection sheaves . . . . . .

MWL – raising/setting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning/removing the guy ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing/releasing the lateral head sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting the MWL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5555555-

15 17 20 22 26 27 29

5555555-

31 33 35 36 39 41 45

5 - 50 55555555-

51 52 54 55 56 60 66 68

Operation from the crane cabin during rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 69 In the submenu Rigging – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 69 In the submenu Operation – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 77

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5.4.1 5.4.2

CHECKLIST: Rigging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 CHECKLIST: MWL – unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10

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MWL – Rigging and unrigging 5.1 Identification and slinging points

5

MWL – Rigging and unrigging The MWL is transported on a separate vehicle, and rigged/unrigged on site.

This chapter describes the necessary rigging work in the usual manner, with checklists which cross-reference to other chapters. First, there is some initial, essential information regarding the identification and position of the slinging points.

5.1

Identification and slinging points

5.1.1

Identification The MWL is designed for the truck crane for which it was delivered. The parts of the MWL belonging to the truck crane have the same serial number as the truck crane. All components are identified by serial numbers.

S H

For technical reasons a truck crane may only be set with one MWL. If you wish to use the MWL on more than one GROVE truck crane, the parts of the MWL must be adjusted for these cranes and labeled with all of the respective serial numbers.

The matching of the MWL may only be carried out by GROVE customer service locally.

s

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S

Only operate the truck crane with those parts of the MWL which have the same serial number as the crane.

The SLI is only set for this MWL. This prevents malfunctions and damage.

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5-1

MWL – Rigging and unrigging 5.1 Identification and slinging points

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

5-2

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MWL – Rigging and unrigging 5.1 Identification and slinging points

5.1.2

G

On the MWL

Slinging points This section shows the intended slinging points for all components which are to be raised during rigging.

Risk of accidents if used incorrectly.

Only attach the lifting gear at the slinging points intended, and only use the lifting gear supplied. In this way you prevent the MWL from moving out of the necessary inclination (ca. 5°) or from swinging and causing injury.

There are four slinging points on the MWL for hoisting, and two slinging points for fastening guide ropes.

Slinging points for hoisting Only use the connection eyes for lifting (1) and (2) on the top chord of the gantry masts.

Suitable slinging tackle, with four lines of different length, is supplied.

Slinging points and lines that belong together are marked with letters.

Slinging points for guide ropes There are two connection eyes (1) on each of the two gantry masts, on the outer side.

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The connection eyes are intended for the attachment of guide ropes.

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5-3

MWL – Rigging and unrigging 5.1 Identification and slinging points

On the other components

When rigging, the rope grab and the lateral head sheaves must also be raised.

Rope grab On the rope grab, two lines of the lifting gear are attached to the cross-strut (1).

Side head sheave

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On the lateral head sheaves, the lifting gear is laid round the rope sheave (2).

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MWL – Rigging and unrigging 5.2 Checklists for rigging work

5.2

Checklists for rigging work This section contains the checklists for rigging and unrigging the MWL:

à p. 5 - 5.

– CHECKLIST: MWL – unrigging; à p. 5 - 10.

– CHECKLIST: Rigging the MWL;

5.2.1

CHECKLIST: Rigging the MWL

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.

1. Prepare the truck crane for rigging;

à Preparing the truck crane, p. 5 - 15.

2. Mount the rests for the rear pendant links on both sides of the main boom basic section; Installing/removing the rests for the rear pendant links, p. 5 - 17.

à

3. Reposition the rope grab in the rear holder or remove for operation with Moving to the rear bracket, p. 5 - 20. the lattice extension;

à

4. Install the lateral head sheaves on the main boom head; removing the lateral head sheaves, p. 5 - 22.

à Installing/

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5-5

MWL – Rigging and unrigging 5.2 Checklists for rigging work

5. The guide ropes and the accompanying slinging tackle should be fastened to the MWL and lifted (observing the marking on the ropes):; Fastening the guide ropes, p. 5 - 28, MWL – slinging, p. 5 - 27.

à à

6. Push in and secure the supports;

à Pushing in the supports, p. 5 - 29.

7. MWL over the main boom and lock to the main boom basic section at Establishing a connection, p. 5 - 31. the front;

à

8. Check whether the sliding connection link for the connection between the holding frame and the main boom; Unlocking the sliding connecting link, p. 5 - 36.

à

9. Lower the MWL slowly with the auxiliary crane and align it in such a way that – The pegs on the holding frame thread into the brackets on the main boom and – The rear pendant links insert into the rests in the main boom basic section; MWL – lowering, p. 5 - 33.

à

à Locking

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10. Connect the holding frame and the main boom on both side; the sliding connecting link, p. 5 - 35.

5-6

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MWL – Rigging and unrigging 5.2 Checklists for rigging work

11. Remove the slinging tackle and the guide ropes from the MWL.

12. Establish the hydraulic connection between the MWL and the main boom; Establishing a connection, p. 5 - 36.

à

13. With the ignition off, establish an electrical connection between the Establishing connection, p. 5 - 39.

MWL and the main boom;

à

14. For the following rigging steps, the hand-held control can be connected to the socket of the right-hand and left-hand derricking cylinder in rotation. Information on connecting and removing the hand-held control; Connecting/removing the hand-held control, p. 5 - 41.

à

15. Connect the holding frame and the main boom on both sides; Establishing a connection, p. 5 - 48.

à

16. Release the turnbuckles from the rear pendant links and move into the Operation position; Moving the turnbuckles for the rear pendant links into the position Operation/Transport, p. 5 - 50.

à

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MWL – Rigging and unrigging 5.2 Checklists for rigging work

17. Release the connection between the gantry masts and the holding Establishing/releasing the connection between the gantry masts and frame; the holding frame, p. 5 - 51.

à

18. If the MWL is to be operated with a luffing jib, the rigging work is completed after this checklist. Further rigging is described in the chapter Operation with the luffing jib and the MWL, p. 8 - 1.

19. Unreel the hoist rope of the hoisting gear concerned and guide to the front, or attach a hoist rope to the side and guide to the front via the main boom head; Running the hoist rope to the main boom head, p. 5 - 54.

à

20. To work with the MWL set down: Bring the deflection sheave for the main hoist rope into the Operation position and lay the main hoist rope on the deflection sheave; Moving the deflection sheaves into the position Operation/Transport, p. 5 - 52, Positioning/removing the hoist ropes on/from the deflection sheaves, p. 5 - 55.

à à

21. MWL – raising;

à MWL – raising/setting down, p. 5 - 56.

22. Bring the deflection sheaves required into the Operation position and lay the hoist rope on the corresponding deflection sheave; Moving the deflection sheaves into the position Operation/Transport, p. 5 - 52, Positioning/removing the hoist ropes on/from the deflection sheaves, p. 5 - 55.

à à

5-8

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H

For work with the MWL set down, continue from point 25.

MWL – Rigging and unrigging 5.2 Checklists for rigging work

23. Slew the superstructure to the rear or to the side and fasten the guy Positioning/removing rope on the lateral head sheaves at both sides; the guy ropes, p. 5 - 60.

à

24. Pull the guy rope slightly taut on both sides and release the lateral head sheave; Securing/releasing the lateral head sheaves, p. 5 - 66.

à

25. Remove the hand-held control and plug the bridging plug into the sockConnecting/removing the hand-held control, p. 5 - 41. ets;

à

26. Further information on rigging work on the main boom head (lifting limit switch, anemometer, reeving the hoist rope) as well as on telescoping, folding out the MWL and bracing the boom system varies depending on the additional equipment rigged; it can be found in the following chapters: p. 6 - 2 – For operation with the MWL and the main boom; p. 7 - 1 – For operation with the MWL and the boom extension; p. 8 - 1 – For operation with the MWL and the luffing jib; – For operation with the MWL and the heavy load lattice extension; p. 9 - 1

à

à

à

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à

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5-9

MWL – Rigging and unrigging 5.2 Checklists for rigging work

5.2.2

CHECKLIST: MWL – unrigging

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.

1. Prepare the truck crane for unrigging. The work required depends on the additional equipment used to operate the truck crane: p. 6 - 10 – For operation with the MWL and the main boom; p. 7 - 1 – For operation with the MWL and the boom extension; p. 8 - 1 – For operation with the MWL and the luffing jib; – For operation with the MWL and the heavy load lattice extension; p. 9 - 1

à

à

à

à

2. Remove the main hoist rope and, if applicable, the auxiliary hoist rope from the deflection sheaves on the raising frame and bring both deflecMoving the deflection sheaves tion sheaves into the transport position; into the position Operation/Transport, p. 5 - 52.

à

3. For the following rigging steps, the hand-held control can be connected to the socket of the right-hand and left-hand derricking cylinder in rotation. Information on connecting and removing the hand-held control; Connecting/removing the hand-held control, p. 5 - 41.

à

H

For working with the MWL set down, continue from Point 8.

4. Pull the guy rope slightly taut on both sides and secure the lateral head Positioning/removing the guy ropes, p. 5 - 60. sheave;

à

5. Loosen the guy rope from the lateral head sheave on both sides, and Positioning/removing the guy ropes, p. 5 - 60. pull it up into the bracket; 27.09.2004

à

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MWL – Rigging and unrigging 5.2 Checklists for rigging work

6. MWL – setting down;

à MWL – raising/setting down, p. 5 - 56.

7. Connect the gantry masts and the connection between the gantry Establishing/releasing the connection bemasts and the holding frame; tween the gantry masts and the holding frame, p. 5 - 51.

à

8. If a luffing jib is rigged, retract the surface into the catcher on the auxiliary hoist, and secure.

9. Wind in the hoist ropes: – Wind in the main hoist rope at least until it is behind the holding frame – Wind in the auxiliary hoist rope (after operation without luffing jib) up to the auxiliary hoist

10. Bring the turnbuckles on the rear pendant links into the Transport posiMoving the turnbuckles for the rear pendant tion on both gantry masts; links into the position Operation/Transport, p. 5 - 50.

à

11. Disconnect the raising cylinder and the main boom on both gantry Disconnecting , p. 5 - 49. masts;

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à

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5 - 11

MWL – Rigging and unrigging 5.2 Checklists for rigging work

12. Remove the hand-held control and plug the bridging plug into the sockConnecting/removing the hand-held control, p. 5 - 41. ets;

à

13. With the ignition off, break the electrical connection between the MWL Breaking connections, p. 5 - 40. and the main boom;

à

14. Disconnect the hydraulic connection between the MWL and the main Disconnecting, p. 5 - 38. boom;

à

15. Fasten the guide ropes and the slinging tackle provided to the MWL (obMWL – Slinging and fastening the serving the marking on the ropes); guide ropes, p. 5 - 27.

à

16. Disconnect the holding frame and the main boom on both sides; Unlocking the sliding connecting link, p. 5 - 36.

à

17. Slowly raise the MWL with the auxiliary crane until the pegs have been pulled out of the holding frame and it is inclined about 5° to the front; MWL – raising, p. 5 - 34.

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à

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MWL – Rigging and unrigging 5.2 Checklists for rigging work

18. Release the locking pin of the MWL at the front on the main boom basic Releasing the consection and raise the MWL from the main boom; nection, p. 5 - 32.

à

19. Pushing out the supports;

à Pushing out the supports, p. 5 - 29

20. Set down the MWL on the separate vehicle, remove the lifting gear and the guide ropes and secure the Mega Wing Lift in transport position; Transporting the MWL, p. 5 - 68.

à

21. Remove both lateral head sheaves from the main boom head; Installing/removing the lateral head sheaves, p. 5 - 22.

à

22. If necessary, reposition the rope grab in the front bracket or install it after Moving to the front bracket, p. 5 - 21. operation with the luffing jib;

à

23. Remove the rests for the rear pendant links on both sides of the main Installing/removing the rests for the rear pendant boom basic section; links, p. 5 - 17.

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à

24. Depending on the driving mode, fasten the main hoist rope to the bumper or reeve the hook block and fasten it to the bumper.

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MWL – Rigging and unrigging 5.2 Checklists for rigging work

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MWL – Rigging and unrigging 5.3 Rigging work

5.3

Rigging work To rig and unrig the MWL you will need an auxiliary crane with sufficient lifting capacity and preferably a working platform, though a ladder can be used for this purpose (a free-standing ladder if at all possible).

5.3.1 For rigging

Preparing the truck crane Before rigging, the points on the checklist which follows must have been carried out.

1. Support the truck crane with an outrigger span of 8.76 x 8.90 m (28.7 x 29.2 ft), and align to the horizontal.

2. Enter the current rigging mode with 0 t counterweight on the SLI.

1100 3. The counterweight version required for crane use with the MWL in accordance with the Lifting capacity table is rigged.

4. If necessary for the job planned, rig the auxiliary hoist: – either for working with the luffing jib Thresholds for the use of – or due to the necessary hoist rope length; the main hoist, p. 1 - 3.

à

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5. For operation without the luffing jib, the catcher is erected when the auxiliary hoist is rigged; Operating instructions GMK 7450 – Auxiliary hoist.

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MWL – Rigging and unrigging 5.3 Rigging work

1100

6. The current rigging mode of the truck crane with the newly-rigged Operating instructions counterweight combination has been entered; GMK 7450 – Crane operation – Operating the safe load indicator.

à

7. The superstructure is in the position required for rigging the MWL and the main boom is lowered to the horizontal.

8. The hoist rope is unreeved and wound up or set down beside the truck crane.

9. For operation with the main boom, the accompanying three-part rope Installing/removing the three-part rope holding rod must be installed; holding rod, p. 6 - 4.

à

For unrigging

The prerequisites for unrigging the MWL vary depending on whether the truck crane is operated with the main boom or with a lattice extension (additional equipment):

à p. 6 - 3, – For operation with the MWL and the boom extension; à p. 7 - 1, – For operation with the MWL and the luffing jib; à p. 8 - 1, – For operation with the MWL and the main boom;

– For operation with the MWL and the heavy load lattice extension; p. 9 - 1.

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à

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.2

Installing/removing the rests for the rear pendant links In order for the rear pendant links to fold properly when the gantry masts are set down, and to provide a surface for them when rigging the MWL, three rests are provided on both sides of the main boom: the rear rest (1), the central rest (2), and the front rest (3).

Installing the rests

When rigging, you must install the rests before placing the MWL on the main boom.

Installing the rear rest

• Fasten the rest (1) to the bracket (3) using the swivel pin (2).

• Fasten the rest for operation using the securing pin (4) in position A.

• Secure both pins into place using the linch pins.

For better access, the rest can initially be fastened in position B with the securing pin (4).

However, before setting down the MWL, the rest must be in position A.

Installing the central rest

• Fasten the rest (1) to the bracket (3) using the swivel pin (2).

• Fasten the rest for operation using the securing pin (4) in position A.

• Secure both pins into place using the linch pins.

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For better access, the rest can initially be fastened in position B with the securing pin (4).

However, before setting down the MWL, the rest must be in position A.

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MWL – Rigging and unrigging 5.3 Rigging work

Installing the front rest

• Fasten the rest (1) to the bracket (3) using the swivel pin (2).

• Swing out the rest and fasten it with the securing pin (4).

• Secure both pins into place using the linch pins.

Removing the rests

When unrigging, you must remove the rests after the MWL has been lifted off.

Removing the rear rest

• Remove the linch pin from the securing pin (4) and the swivel pin (2).

• Hold the rest (1) and remove both pins from the holder (3).

• Take the rest from the holder and insert the securing pin (4) and the swivel pin (2) into the rest (1).

• Secure both pins using the linch pins.

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• Stow the rest on the separate vehicle.

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MWL – Rigging and unrigging 5.3 Rigging work

Removing the central rest

• Remove the linch pin from the securing pin (4) and the swivel pin (2).

• Hold the rest (1) and remove both pins from the holder (3).

• Take the rest from the holder and insert the securing pin (4) and the swivel pin (2) into the rest (1).

• Secure both pins using the linch pins.

• Stow the rest on the separate vehicle.

Removing the front rest

• Remove the linch pin from the securing pin (4) and the swivel pin (2).

• Hold the rest (1) and remove both pins from the holder (3).

• Take the rest from the holder and insert the securing pin (4) and the swivel pin (2) into the rest (1).

• Secure both pins using the linch pins.

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• Stow the rest on the separate vehicle.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.3

Moving the rope grab Truck cranes which are equipped with the MWL have two brackets for the rope grab, the front bracket and the rear bracket: – When rigging, you must the rope grab to the rear bracket (unless it has remained there since the last job).

– When unrigging, the rope grab must be moved to the front bracket if the next job is to be undertaken without the MWL. If the MWL is to be used during the next job as well, the rope grab can stay in the rear bracket for the journey.

Moving to the rear bracket

Use only lifting gear with sufficient lifting capacity. Weight specifications; Transport dimensions and weights, p. 2 - 1.

à

• Fasten the lifting gear (4) to the rope grab (1).

• Align the rope grab with the auxiliary crane.

• Loosen the linch pins and pull out the pins (2) from both sides of the front bracket (3).

• Lift off the rope grab from the front bracket.

For operation with the luffing jib, you must set down the rope grab; in this case, the following steps do not apply.

• Make sure that the hoist rope (4) does not get trapped under the rope grab.

• Lift the rope grab (1) onto the rear bracket (3) and align the locking points.

• Fasten the rope grab to the rear bracket on both sides using the pins (2).

• Secure the pins using the linch pins.

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• Set down the rope grab on the main boom.

• Remove the lifting gear.

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MWL – Rigging and unrigging 5.3 Rigging work

Moving to the front bracket

H

Use only lifting gear with sufficient lifting capacity. Weight specifications;

à Transport dimensions and weights, p. 2 - 1.

When the luffing jib was used for the previous job, the rope grab will have been removed. In this case, you must sling the rope grab and fasten it to the front bracket.

• Fasten the lifting gear (4) to the rope grab (1).

• Align the rope grab with the auxiliary crane.

• Loosen the linch pins and pull out the pins (2) from both sides of the rear bracket (3).

• Lift off the rope grab from the rear bracket.

• Lift the rope grab (1) onto the front bracket (3) and align the locking points.

• Fasten the rope grab to the front bracket on both sides using the pins (2).

• Secure the pins using the linch pins.

• Set down the rope grab on the main boom.

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• Remove the lifting gear.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.4

Installing/removing the lateral head sheaves The guy ropes of the winches are attached to the main boom head by means of additional lateral head sheaves.

– When rigging, you must install the lateral head sheaves on both sides.

– When unrigging, you must remove the lateral head sheaves on both sides in order to attain an axle load of max. 12 t (26 400 lbs).

Installing the head sheave

H

• Use only lifting gear with sufficient lifting capacity. Weight specifications;

à Transport dimensions and weights, p. 2 - 1.

Check whether the three-section rope holding rod is installed in the main boom head. After installing the lateral rope sheaves, the continuous rope Installing/removing the three-part holding rod can no longer be pulled out; rope holding rod, p. 6 - 4.

à

• Check if the joint on the bearing block is locked. The locking pins (2) must be in the bearing points (1) and secured with the linch pins.

• Loosen the screws and remove the cover (3) from the axle (4) on the main boom head.

• Attach the lifting gear to the head sheave (1).

• Fasten a guide rope (5) to the handle of the head sheave.

• Lift the head sheave onto the main boom head from the side.

• Align the head sheave so that the bearing

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point (2) lines up with the axle (4).

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MWL – Rigging and unrigging 5.3 Rigging work

G H

Risk of accidents from falling head sheaves!

Secure the head sheave with a guide rope before fastening the cover to the axle. In this way, you prevent being pushed from the ladder by the head sheave slipping down accidentally.

The following diagrams only show the lateral head sheave on the left-hand side. On the right-hand side, installation is carried out in the same way.

• Push the head sheave (1) onto the axle (4) with the bearing point (2).

• Secure the head sheave in this position with the guide rope (5) so that it does not slip off to the side. Fasten the guide rope, e.g. to the fixed point of the rope (6).

• Place the cover (3) onto the axle (4) and secure it with the screws (tightening torque 180 Nm (133 lbs ft)).

• Swing the head sheave (1) to the rear with the auxiliary crane until the bore hole (4) lines up with the bracket (6).

• Release the linch pin and remove the locking pin (7) from the bracket (2).

• Remove the securing pin (3) from the bracket (2).

• Push the securing pin (3) through the bore hole (4) and into the bracket (6).

• Secure the securing pins (3) in the bracket (6) with the locking pins (7).

• Secure the locking pin with the linch pin.

• Remove the lifting gear and the guide rope (5) from the head sheave (1).

• Install the lateral head sheave on the right-hand side in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

Removing the head sheave

G

• Use only lifting gear with sufficient lifting capacity. Weight specifications;

à Transport dimensions and weights, p. 2 - 1.

Danger of injury from head sheave tilting out unexpectedly.

Before removing, always check whether the joint on the bearing block is blocked by the locking pin, and pull the lifting gear lightly taut with the auxiliary crane before loosening the securing pin.

In this way you prevent the head sheave from tilting to the side or to the rear when the securing pins are released, and causing injury to yourself or others.

• Check if the joint on the bearing block is locked. The locking pins (2) must be in the bearing points (1) and secured with the linch pins.

• Attach the lifting gear to the head sheave (1).

• Fasten a guide rope (5) to the handle of the head sheave.

• Align the lateral head sheave with the auxiliary crane in such a way that the securing pin (3) is relieved of its load in the bracket (6).

• Release the linch pin and remove the locking pin (7) from the bracket (6).

• Push the securing pin (3) out of the bore hole (4) and the bore hole bracket (6).

• Fasten the securing pins (3) in the bracket (2) with the locking pins (7).

Risk of accidents from falling head sheaves!

Secure the head sheave with a guide rope before releasing the cover on the axle. In this way, you prevent being pushed from the ladder by the head sheave slipping down accidentally.

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G

• Secure the locking pin with the linch pin.

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MWL – Rigging and unrigging 5.3 Rigging work

G H

Risk of accidents due to swinging head sheave.

Always align the head sheave to the vertical so that it does not swing when it is pulled from the axle. Stand on the ground slightly to one side at the front of the main boom head and use the guide rope to pull the head sheave from the axle. This means you are out of the danger area should the head sheave swing.

The following diagrams only show the lateral head sheave on the left-hand side. On the right-hand side, installation is carried out in the same way.

• Align the head sheave to the vertical with the auxiliary crane: – The axle of the head sheave (1) must be vertically above the cover (2) and – The lifting gear (6) must point vertically upwards.

• Secure the head sheave in this position with the guide rope (5) so that it does not slip off to the side. Fasten the guide rope, e.g. to the fixed point of the rope (4).

• Stand slightly to the side at the front of the main boom head.

• Loosen the screws and remove the cover (2) from the axle (3) on the main boom head.

• Loosen the guide rope (5) from the rope fixed point (4).

• Pull the head sheave from the axle (3) with the guide rope.

• Set down the head sheave and remove the lifting gear (6) and the guide rope.

• Place the cover (2) onto the axle (3) and se-

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cure it with the screws.

• Remove the lateral head sheave on the other side in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.5

Using the rigging tool At some positions it is not possible to knock out the pins from the inside. For these connections, an appropriate rigging tool is provided to release the pins.

S

Risk of accidents if used incorrectly.

Only use the rigging tool to release the heavy pins, and not to knock them out. In this way you prevent being knocked off balance by the great weight of the pins, and falling from the ladder.

The rigging tool consists of a rod (1) with a striking weight (2).

One end of the rod, and the pins to which it corresponds, have matching threads (4) and (5).

• Screw the rod and as far as it will go into the pin (3).

• Push the striking weight up to the pin and then hit it out as far as it will go. Repeat this procedure only until the pin is released.

• Remove the rigging tool.

• Pull the pin out of the connecting point by

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hand.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.6 MWL – slinging

S

MWL – Slinging and fastening the guide ropes During installation and removal, the MWL must be slung with the slinging tackle supplied. Only with this lifting gear will you attain the inclination necessary for installation.

Danger of damage if incorrect lifting gear is used!

Only use the slinging tackle supplied, since this means that the MWL will automatically be at the inclination required for installation, i.e. an angle of around 5° to the front.

Hang the slinging tackle provided on the hook of the auxiliary crane.

Single hook

• Hang the slinging tackle (3) directly onto the single hook (4).

Double hook

• Attach additional lifting gear (2) with sufficient lifting capacity onto the double hook (1).

• Hang the supplied slinging tackle (3) onto this lifting gear.

• Position the hook block (5) of the auxiliary crane centrally above the longitudinal axle of the MWL. Slinging points and lines that belong together are marked with letters (A and B).

• Fasten the two shorter lines (2) to the rear connection eyes (1).

• Fasten the two shorter lines (4) to the rear

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connection eyes (3).

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MWL – Rigging and unrigging 5.3 Rigging work

Fastening the guide ropes

Always fasten the guide ropes to the MWL so that you can position it better at the locking point after raising.

• Fasten one guide rope (1) on each side, us-

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ing the outside connection eyes (2) at the front.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.7 Pushing in the supports

S

Push the supports in/out In order to push in the supports, the MWL must be raised with the auxiliary crane; when this is done, you can push in the supports.

Risk of damage due to supports not being pushed in If the supports are not pushed in, the cooling water cooler, the fuel tank and the derricking cylinder will be damaged when the MWL is lowered onto the main boom. Push the supports in when the MWL is raised with the auxiliary crane.

• Release the retaining pin (2) and remove the pin 3) from the bearing point.

• Push the support (1) upwards.

• Reinsert the pin into the support and secure it with the retaining pin.

• Push in all the other supports too.

Pushing out the supports

Risk of injury through improper handling Always keep a firm hold on the lower part of the support when removing the pin. Otherwise the support could fall off and cause injury.

s

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G

In order to set down the MWL on the ground or onto a vehicle for transportation, the supports must be pushed out.

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MWL – Rigging and unrigging 5.3 Rigging work

• Remove the retaining pin (2).

• Raise the support slightly and pull the pin (3) from the bore.

• Lower the support (1) until the bores holes in the support and in the guide tube align.

• Reinsert the pin (3) into the bore and secure it with the retaining pin (2).

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• Push out all the other supports too.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.8

Establishing/breaking the hydraulic connection between the MWL and the main boom The locking points between the MWL and the main boom are at the front, on the collar of the main boom basic section.

Establishing a connection

• Sling the MWL to the auxiliary crane and attach both guide ropes. Only use the slinging tackle provided and the slinging points intended; p. 5 - 27.

à

After raising, the MWL will be at an inclination of ca. 5° so that the locking points can be aligned more easily.

• Raise the MWL above the main boom basic section.

• Align the MWL in such a way that the locking points (5) and (6) engage and align on both sides

• Release the retaining pin and remove the locking pin (3) from the bracket (4).

• Take the pin (1) out of the bracket (2) and insert it as far as it will go through the locking points (5) and (6).

• Insert the locking pin (3) into the bracket (4) and secure it with the retaining pin.

• Connection on the other side is carried out in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

Releasing the connection

• The following requirements must be met before releasing the connection: – The MWL is slung to the auxiliary crane at the slinging points intended and using the slinging tackle supplied, and the guide ropes are attached; p. 5 - 27.

à

– The connection between the holding frame and the main boom is broken; p. 5 - 36.

à

– The MWL is raised to ca. 5° and the pegs are pulled out of the holding MWL – raising, p. 5 - 34. frame;

à

S H

Risk of damage to the MWL unit and main boom!

Position the hook block of the auxiliary crane above the longitudinal axis of the MWL. In this way you prevent the MWL from canting in the locking points and damaging them.

To loosen the pins, use the pin rigging tool supplied;

à p. 5 - 26.

• Release the retaining pin and remove the locking pin (3) from the bracket (4).

• Pull the pin (1) from the locking points (5) and (6) and insert them into the bracket (2).

• Insert the locking pin (3) into the bracket (4) and secure it with the retaining pin.

• Release the connection on the opposite side in the same way.

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• Lift the MWL from the main boom with the auxiliary crane.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.9

MWL – lowering/raising on the main boom When rigging, you must lower the MWL onto the rear of the main boom using the auxiliary crane. When rigging, you must raise the MWL from the main boom using the auxiliary crane.

MWL – lowering

S

When rigging, you must lower the MWL with the auxiliary crane in order to be able to connect the holding frame and the basic section.

Danger of damage to the rear pendant links!

When lowering the MWL, make sure that the rear pendant links thread into the brackets and that the pegs thread into the retainers on the main boom.

In this way you prevent damage to the rear pendant links or to the retainers.

• Check that the sliding connecting links (3) are open on both sides;

à p. 5 - 36.

• Slowly lower the MWL with the auxiliary crane, making sure that, on both sides: – The rear pendant links thread into the brackets (2) and – The pegs (5) thread into the retainers (4).

• The pegs may engage more easily if you align the holding frame using the handle (1).

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MWL – Rigging and unrigging 5.3 Rigging work

MWL – raising

S S

When rigging, you must raise the MWL with the auxiliary crane in order to be able to disconnect the MWL and the main boom.

Risk of damage to the raising cylinder and rear pendant links!

Before raising, check that on both sides – the connection between the raising cylinder and the main boom has been broken and – the turnbuckles for the rear pendant links are in the Transport position.

In this way you prevent the rear pendant links from hanging down when raising and thereafter lowering the MWL, and also prevent the raising cylinders from being caught on the basic section and damaged.

Risk of damage to electric cables and hydraulic hoses.

Before raising, check that the electrical and hydraulic connections have been broken. In this way you prevent damage to the connecting cables and hydraulic hoses when the MWL is raised and thereafter lowered.

• Check that on both sides: – the sliding connecting link (3) is opened; p. 5 - 36.

à

– the turnbuckles (2) for the rear pendant links are in the Transport position; p. 5 - 50.

à

– the connection (6) between the raising cylinder and the main boom has been broken; p. 5 - 51.

à

• Slowly raise the MWL with the auxiliary crane and make sure that on both sides the pegs (5) thread evenly out of the retainers (4).

• The pegs may disengage more easily if you align the holding frame using the handle (1).

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H

Raise the MWL until it is inclined at an angle of about 5° so that it is in the correct position for the next stage – releasing the connection between the MWL and the main boom.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.10

Connecting/disconnecting the holding frame and main boom When the MWL is lowered, the pegs on the holding frame thread into the retainers on the main boom on both sides. The connection between the pegs and the retainers is created via sliding connecting links.

– To create the connection, you must lock the sliding connecting link.

– To disconnect, you must unlock the sliding connecting link.

Locking the sliding connecting link

• Check that the pegs of the holding frame are completely engaged in the retainers on the main boom on both sides;

à MWL – lowering, p. 5 - 33.

• Release the retaining pin (2) and pull out the pin (3).

• Pull the locking bar (1) to the rear until its front bore holes are lined up with the bore holes in the bracket (4).

• Insert the pin through the bore holes as far as they will go.

• Secure the pin with the retaining pin.

• Lock the sliding connecting link on the opposite side in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

Unlocking the sliding connecting link

G

• Check whether the connections between the holding frame and the gantry masts have been established;

à p. 5 - 51.

Risk of accidents when operating with sliding connecting links unlocked Unlock the sliding connecting link only when unrigging the MWL with a connection established between the holding frame and the gantry masts.

When operated with the sliding connecting link unlocked, the holding frame may be pulled out of the retainers. This will cause damage to the boom system, and the boom may bend due to overload, causing the load to be dropped and the truck crane to overturn.

• Release the retaining pin (2) and pull out the pin (3).

• Pull the locking bar (1) to the front until its rear bore holes are lined up with the bore holes in the bracket (4).

• Insert the pin through the bore holes as far as they will go.

• Secure the pin with the retaining pin.

• Unlock the sliding connecting link on the opposite side in the same way.

5.3.11

Establishing/disconnecting the hydraulic connection

H

When rigging, you must establish the hydraulic connections. The hydraulic hoses can be found in a holder on the right-hand gantry mast.

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Establishing a connection

Turn off the crane engine before establishing or breaking the connection.

Otherwise, the pressure in the quick couplings will be so great that it will be difficult or impossible to release the connection by hand.

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MWL – Rigging and unrigging 5.3 Rigging work

S H

Risk of damage to the electrical cables.

Disconnect the electrical connection cables from the dummy sockets on the MWL before taking the hydraulic hoses out of the holder. In this way you prevent the hydraulic hoses from being caught on the connection cables and damaging them.

Check the quick couplings for contamination (e.g. grains of sand) and clean them if necessary before establishing the hydraulic connections. In this way you prevent leaks and malfunctions when the connections are established.

• Pull out the plug (3) from the dummy socket (6).

• Close the dummy socket (6).

• Pull out the plug (4) from the dummy socket (5).

• Take the hydraulic hoses (2) from the holder (1) along with the electrical connection cables.

• Run the hydraulic hoses (2) to the hydraulic connections (1) on the main boom head.

• Remove the protective caps from the hydraulic hoses and the hydraulic connections.

The allocation of the hoses and the connections can be established from their size and a colour coding (3).

• Connect the hydraulic hoses (2) to the con-

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nections (1).

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MWL – Rigging and unrigging 5.3 Rigging work

Disconnecting

S

When unrigging, you must disconnect the hydraulic connections.

Risk of damage to the electrical cables.

Disconnect the electrical connection first. In this way you prevent the hydraulic hoses from being caught on the connection cables and damaging them.

• Check whether the plugs (3) and (4) on the electrical connection cables have been unplugged, and unplug them if necessary; p. 5 - 40.

à

• Remove the hydraulic hoses (1) from the connections (2).

• Close the hydraulic hoses and the hydraulic connections with the protective caps.

• Run the hydraulic hoses (2) to the rear along with the electrical connection cables, and hang them on the holder (1).

• Insert the plug (3) into the dummy socket (6).

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• Insert the plug (4) into the dummy socket (5).

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5.3.12 Establishing connection

S S

Establishing/disconnecting the electrical connection When rigging, you must establish the electrical connections. The electrical connections are on the front right-hand side of the main boom head.

Risk of malfunction in the superstructure electronics!

Always turn off the ignition on the superstructure before you establish or break the electrical connection. In this way you prevent malfunctions in the superstructure electronics and corresponding error messages in crane operation thereafter.

Danger of damage to the connecting cable.

Make the hydraulic connection first. In this way you prevent the hydraulic hoses from being caught on the connection cables and damaging them.

Changing over the bridging plug

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

Establishing connections The plugs of the connection cable (3) and (4) were unplugged from the dummy sockets of the MWL when the hydraulic connection was established, since they are attached to the hyp. 5 - 38. draulic hoses;

à

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

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

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MWL – Rigging and unrigging 5.3 Rigging work

Breaking connections

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When unrigging, you must disconnect the electrical connections.

Risk of malfunction in the superstructure electronics!

Always turn off the ignition on the superstructure before you establish or break the electrical connection. In this way you prevent malfunctions in the superstructure electronics and corresponding error messages in crane operation thereafter.

Disconnecting

• Pull out the plug (3) from the socket (2).

• Close the socket (2) with the cap and reposition the bracket.

• Pull out the plug (4) from the socket (1).

The connection cables (3) and (4) are attached to the hydraulic hoses. This means that they are only connected to the dummy sockets of the MWL after the electrical connection has p. 5 - 36. been broken;

à

Changing over the bridging plug

• Remove the bridging plug (2) from the dum-

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my socket (3) and plug it into the socket (1).

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.13

Connecting/removing the hand-held control When rigging, you can use the hand-held control to operate the raising cylinders, the winches and the tilt cylinders. To do this, you must connect the hand-held control.

For the hand-held control, the sockets (1) to (4) are used on the derricking cylinders.

If the hand-held control for the is connected to another socket on the truck crane, none of the keys will work, or are assigned to other functions.

Only certain functions can be carried out from each socket. Overview of possible functions; Connections for hand-held control, p. 4 - 27.

à

Hand-held control (for serial no. 9020 and above) Connecting the hand-held control

• Open the cap (2).

• Remove the bridging plug (3) from the socket (1).

If you pull out the bridging plug while the crane engine is running, the crane engine will turn off.

• Insert the plug (4) of the hand-held control into the socket (1).

• Secure the plug (4) with the cap (2).

• Wait about 20 seconds until the CAN indica27.09.2004

tor lamp (5) goes on. The ignition is now switched on and the Charge control indicator lamp (6) lights up.

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MWL – Rigging and unrigging 5.3 Rigging work

If the CAN indicator lamp does not light up or flash after approx. 20 seconds, Malfunctions when operating with the hand-held conthere is a malfunction; trol, p. 10 - 6.

à

H

When the hand-held control is connected, the ignition cannot be switched off from the crane cab.

Disconnecting the hand-held control

• Open the cap (2).

• Remove the plug (4) of the hand-held control from the socket (1).

When the plug is pulled out, the ignition on the superstructure will be switched off automatically and the CAN (5) and Charge control (6) indicator lamps will go out.

• Insert the bridging plug (3) into the socket (1).

• Secure the bridging plug (3) with the cap (2).

H

Danger from unauthorized use!

Always keep the hand-held control in the driver’s cab or in crane cab and lock the doors after leaving the truck crane. In this way you can stop unauthorized persons from starting the crane engine with the hand-held control.

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G

Always insert the bridging plug after removing the hand-held control. In this way you prevent malfunctions when you connect the hand-held control to another socket. The hand-held control is only ready for operation when bridging plugs are inserted in all the sockets which are not being used.

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MWL – Rigging and unrigging 5.3 Rigging work

Hand-held control (up to serial no. 9019) Connecting the hand-held control

• Loosen the collar nut and pull the bridging plug (2) out of the socket 1).

If you pull out the plug while the crane engine is running, the crane engine will turn off.

• Insert the plug (3) of the hand-held control into the socket (1) and secure it with the collar nut.

• Wait about 20 seconds until the CAN indicator lamp (4) goes on. The ignition is now switched on and the Charge control indicator lamp (5) lights up.

If the CAN indicator lamp does not light up or flash after approx. 20 seconds, there is a malMalfunctions when operating with function; the hand-held control, p. 10 - 6.

à

H

When the hand-held control is connected, the ignition cannot be switched off from the crane cab.

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MWL – Rigging and unrigging 5.3 Rigging work

Disconnecting the hand-held control

• Loosen the collar nut and pull the plug (3) of the hand-held control from the socket (1).

When the plug is pulled out, the ignition on the superstructure will be switched off automatically and the CAN (4) and Charge control (5) indicator lamps will go out.

• Insert the bridging plug (2) into the socket (1) and secure it with the collar nut.

H

Risk posed by unauthorized use.

Always keep the hand-held control in the driver’s cab or in crane cab and lock the doors after leaving the truck crane. In this way you can stop unauthorized persons from starting the crane engine with the hand-held control.

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G

Always insert the bridging plug after removing the hand-held control. In this way you can prevent malfunctions when you connect the hand-held control to another socket. The hand-held control is only ready for operation when bridging plugs are inserted in all the sockets which are not being used.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.14

Connecting/disconnecting the raising cylinder and main boom The connection between the raising cylinder and the main boom is made on both sides in front of the pivot point of the derricking cylinder.

To establish and break this connection, you must raise or lower the raising cylinder with the tension ratchets and move the raising cylinders individually. Operation of the tension ratchets, and the procedure for moving the raising cylinder, will be described first in separate sections.

Operating the tension ratchets

H

You can use the tension ratchets to lower the raising cylinder onto the connection point and to raise it for transport.

If the tension ratchet is integrated at a rotation of 180°, the section Raising applies for lowering and the section Lowering applies for raising.

Lowering the raising cylinder

• Press in the locking bar (1) in direction A. • Pump the lever (2) once.

The raising cylinder is lowered by anti-clockwise movements.

Raising the raising cylinder

• Press in the locking bar (1) in direction B. • Pump the lever (2) once.

The raising cylinder is raised by clockwise movements.

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MWL – Rigging and unrigging 5.3 Rigging work

Moving the raising cylinder

When rigging, the hand-held control is used for operation. If the hand-held control is defective, you can also carry out the functions from the crane cab; p. 5 - 60.

à

Switching over the hydraulic circuit In order to align the locking points, you can move the raising cylinder separately. To do this, you must switch over the hydraulic circuit. There are two switching positions: – One switching position for moving the left-hand cylinder – One switching for moving both raising cylinders simultaneously.

In this switching position, you can also move the right-hand raising cylinder alone by locking the left-hand raising cylinder first.

To switch over the hydraulic circuit, there is a valve with lever (1) on the left-hand gantry mast.

• Move the lever into the position required: Left-hand raising cylinder move alone

Position B (to the front):

Both raising cylinders move simultaneously

Risk of damage through incorrect switching position.

After locking the raising cylinder, the lever must always be in position B. Otherwise, only the left-hand raising cylinder will move when the MWL is raised and the system will be put under pressure, causing damage.

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S

Position A (to the rear):

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MWL – Rigging and unrigging 5.3 Rigging work

Moving the raising cylinder To move the raising cylinder, you can connect the hand-held control to the socket on either the left-hand or right-hand derricking cylinder.

• Connect the hand-held control to the desired socket.

Connecting the hand-held control;

P 9 8

à p. 5 - 41.

• Start the crane engine by pressing Start.

Release the button as soon as the crane engine is running.

• Press the MWL Raise/set down pre-selection button.

When the button is pressed, the red diode in the button will light up.

• Press and hold the Direction button r.

• To Move out the raising cylinder, also press the Right/up movement button (1).

• To Retract the raising cylinder, also press the Left/down movement button (2).

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5 - 47

MWL – Rigging and unrigging 5.3 Rigging work

Establishing a connection

Create the connection on the left-hand side first and then the connection on the right-hand side. In this way, you can move the raising cylinders individually.

• Move the hydraulic circuit into switch position A to move the left-hand raising cylinder;

à Switching over the hydraulic circuit, p. 5 - 46.

• First lower the left-hand raising cylinder (2) with the tension ratchet (5) and extend it far enough for the connection points (3) to line up.

Operating the tension ratchets, p. 5 - 45, Moving the raising cylinder, p. 5 - 47.

à à

• Remove the retaining pin and pull the bolt (1) out of the holder (4).

• Insert the pin (1) into the connection points (3) and secure it with the retaining pin.

• Remove the tension ratchet (5) from the bracket (4) on the raising cylinder (2).

• Fold up the tension ratchet into the Operation position and fasten it to the holder (6).

• Move the hydraulic circuit into switch position B to move both raising cyl-

à

• Connection on the other side is carried out in the same way.

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p. 5 - 46). Since the left-hand raising cylinder is already locked, inders ( you can also move the right-hand raising cylinder on its own in this switch position.

MWL – Rigging and unrigging 5.3 Rigging work

Disconnecting

Before breaking the connection, the gantry masts must be set down and a connection must be established between the winches and the holding frame.

Disconnect the right-hand side first and then the left-hand side. In this way, you can move the raising cylinders individually.

• Move the hydraulic circuit into switch position B to move both raising cylinders;

à Switching over the hydraulic circuit, p. 5 - 46.

• First, remove the right-hand tension ratchet (5) from the bracket (6) and fold the tension ratchet down.

• Fasten the tension ratchet (5) to the bracket (4).

• Release the pin (1) in the connection points (3) by raising the raising cylinder (2) with the tension ratchet (5) and extending it slightly.

• Unscrew the retaining pin from the pin (1).

• Pull the pin (1) out of the connection points (3).

• Insert the pin (1) into the bracket (4) and secure it with the retaining pin.

• Retract the raising cylinder (2) as far as it will go and raise it as far as possible with the tension ratchet (5).

Move the hydraulic circuit to position A in order to move the left-hand raising cylinder p. 5 - 46) and break the connection on the ( left-hand side in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.15

Moving the turnbuckles for the rear pendant links into the position Operation/Transport Each gantry mask has a turnbuckle which is used to fasten the rear pendant links.

– When rigging, the turnbuckles must be removed from the rear pendant links and moved into the Operation position before you raise the gantry masks.

– When unrigging, the turnbuckles must be fastened to the rear pendant links in the Transport position.

Moving into the operating position

• Release the retaining pin and remove the pins (3) from the bracket (4).

• Fold the turnbuckle (2) upwards.

• Use the pin (3) to fasten the turnbuckle at the bracket (1).

• Secure the pin with the retaining pin.

• Bring the turnbuckle on the other side into the Operation position in the same way.

Moving into the transport position

• Release the retaining pin and remove the pins (3) from the bracket (1).

• Fold the turnbuckle (2) downwards.

• Use the pin (3) to fasten the turnbuckle at the bracket (4).

• Secure the pin with the retaining pin.

• Bring the turnbuckle on the other side into

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the Transport position in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.16

Establishing/releasing the connection between the gantry masts and the holding frame The gantry masts are attached to the holding frame with two pins each.

– When rigging, you must break the connection before raising the gantry masts.

– When rigging, you must establish the connection so that the MWL can be completely raised from the main boom.

Disconnecting

• Loosen the retaining pin and remove the locking pin (3).

• Pull the pin (1) out of the connection points (4).

• Reinsert the pin (1) into the brackets (2).

• Secure the pin with the locking pin (3).

• Secure the locking pin with the retaining pin.

• Break the connection on the opposite side in the same way.

Connecting

• Loosen the retaining pin and remove the locking pin (3).

• Pull the bolts (1) out of the holders (2).

• Reinsert the pin (1) into the connection points (4).

• Secure the pin with the locking pin (3).

• Secure the locking pin (3) with the retaining pin.

• Establish the connection on the other side in

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the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.17

Moving the deflection sheaves into the position Operation/ Transport There are two deflection rolls on the raising frame. The right-hand deflection sleeve (1) is required for the main hoist rope. The left-hand deflection sleeve (2) is required for the auxiliary hoist rope.

– When rigging, you must move the deflection sheave required into the Operation position.

– When rigging, you must bring both deflection sheaves into the Transport position before you set down the gantry masts.

Moving into the position Operation

S

The deflection sheave for the main hoist rope can also be moved into the Operation position when the gantry masts have been set down.

The deflection sheave for the auxiliary hoist rope can only be moved into the Operation position with the gantry masts raised.

Risk of damage to the deflection sheave and the main boom.

While the left-hand deflection sheave (2) for the auxiliary rope is in the Operation position, you must on no account set down the MWL on the main boom. In this way you prevent the deflection sheave being pressed against the main boom when the MWL is set down, causing damage to both the deflection sheave and the main boom.

With raised MWL

• Loosen the retaining pin and pull out the bolt (1).

• Turn the deflection sheave (2) as far to the right as possible.

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

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If the auxiliary hoist rope is to be reeved as well for operation, move the left-hand deflection sheave (3) into the Operation position in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

With MWL set down

• Loosen the retaining pin and pull out the bolt (1).

• Turn the deflection sheave (2) for the main hoist rope as far to the right as possible.

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

The left-hand deflection sheave (3) for the auxiliary hoist rope can only be moved into the Operation position when the MWL is raised.

Moving into the Transport position

The deflection sheave for the auxiliary must only be moved into the Transport position when the gantry masts have been raised.

With raised MWL

• Loosen the retaining pin and pull out the bolt (1).

• Turn the deflection sheave (2) as far to the left as possible.

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

If the auxiliary hoist rope was reeved as well for operation, move the left-hand deflection sheave (3) into the Transport position in the same way.

H

You can also move the deflection sheave for the main hoist rope into the Transport position when the gantry masts are set down, e.g. after operation with MWL set down.

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MWL – Rigging and unrigging 5.3 Rigging work

With MWL set down

• Loosen the retaining pin and pull out the bolt (1).

• Turn the deflection sheave (2) as far to the left as possible.

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

The left-hand deflection sheave (3) for the auxiliary hoist rope must be moved into the Transport position before the MWL is set down.

5.3.18

Running the hoist rope to the main boom head Depending on the rigging mode, you must either reel off the hoist rope and run it to the front or raise the lateral hoist rope onto the main boom.

• Run the main hoist rope (4) and if necessary also the auxiliary hoist rope (3): – Over the rope grab (1) in the rear bracket and – Over the raising frame (2) and

H 5 - 54

The further course of the hoist ropes depends on whether or not the use of the lattice extension is planned, and is described later, in the corresponding chapters on operating the MWL.

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– Over the main boom head to the front.

MWL – Rigging and unrigging 5.3 Rigging work

5.3.19

Positioning/removing the hoist ropes on/from the deflection sheaves When rigging, the hoist ropes required are already pulled to the front and lie next to the deflection sheaves on the raising frame.

When rigging, the hoist ropes are already unreeved from the hook block.

G

Risk of accidents due to falling parts.

Always secure the pins of the rope protection roll with retaining pins. In this way you prevent parts from coming loose, falling off and causing injury; you also prevent the unsafe hoist rope from sliding off the deflection sheave.

With raised MWL

• Remove the retaining pin from the pin (2) and remove the rope protection roll (1).

• When rigging, lay the main hoist rope (4) on the deflection sheave (3) and, if required, lay the auxiliary hoist rope (5) on the deflection sheave (6).

• When unrigging, remove the hoist ropes which were laid from the deflection sheaves (3) and (6) and place them beside the deflection sheave.

• Fasten the rope protection roll (1) with the pin (2) and secure the pin with the retaining pin.

• If necessary, also fasten the rope protection roll to the deflection sheave (6).

With MWL set down

• Remove the retaining pin from the pin (2) and remove the rope protection roll (1).

• When rigging, lay the main hoist rope (4) on the deflection sheave (3) and run it over the raising frame to the front.

• When unrigging, remove the main hoist rope from the deflection sheave (3).

• Fasten the rope protection roll (1) with the 27.09.2004

pin (2) and secure the pin with the retaining pin.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.20

MWL – raising/setting down When raising and setting down, both gantry masts are always raised and set down simultaneously. The raising cylinders are extended and retracted correspondingly.

Preparations

You can only raise and set down the MWL when – the electrical connection has been established; – the hydraulic connection has been established;

H

à p. 5 - 39 and à p. 5 - 36.

When rigging, the hand-held control is used for operation. If the hand-held control is defective, you can also carry out the functions from the crane cab; p. 5 - 69.

à

• Connect the hand-held control to either the socket on the left-hand derricking cylinder or to the socket on the right-hand derricking cylinder; Connecting the hand-held control, p. 5 - 41.

à

P MWL – raising

• Start the crane engine by pressing Start.

• Release the button as soon as the crane engine is running.

• Before raising, check that the following conditions are met: – The connections between the raising cylinders and the main boom have been established and the tension ratchets are secured in the Operation position; p. 5 - 45.

– The turnbuckles for the rear pendant links are in the Operation position; p. 5 - 52.

– The connections between the gantry masts and the holding frame have p. 5 - 51. been broken; – The lever in the hydraulic circuit of the raising cylinder is in position B p. 5 - 46. for simultaneous movement of both raising cylinders;

à

à

à

5 - 56

Risk of damage through incorrect switching position.

Before raising the MWL, check that the lever of the hydraulic circuit of the raising cylinders is in position B. Otherwise, only the left-hand raising cylinder will move when the MWL is raised and the system will be put under pressure, causing damage.

Risk of damage from tension ratchets or turnbuckles which have not been loosened.

Make sure that the tension ratchets and the turnbuckles are in the Operation position before you raise the MWL. In this way you prevent the turnbuckles or tension ratchets from counteracting the raising, which could cause damage to these components, to the rear pendant links or to the raising cylinders.

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S S

à

MWL – Rigging and unrigging 5.3 Rigging work

9 8

• Press the MWL Raise/set down pre-selection button.

When the button is pressed, the red diode in the button will light up.

• Press and hold the Direction button r.

• Also press the Right/up movement button. The MWL will be raised.

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

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

5

When the end position MWL raised 90° has been reached, the green diode in the Locking status indicator lamp will light up.

• If you no longer require the hand-held control, unplug it from the socket;

à p. 5 - 42.

Setting down the MWL

• Before setting down, check that the following conditions are met: – – – –

The boom system is not braced.

The main boom is at an angle under 5°. p. 5 - 66.

The lateral head sheaves are secured; The guy ropes have been removed from the lateral head sheaves; p. 5 - 60.

– The left-hand deflection sheave for the auxiliary hoist rope on the raisp. 5 - 53. ing frame is the the Transport position;

à

à

à

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S S

Risk of damage if the guy ropes are not removed.

Make sure that the guy ropes have been removed from the lateral head sheaves before setting down the MWL. In this way you prevent the securing pins from being put under excessive strain, which could also cause damage to the lateral head sheaves when the MWL is set down again.

Risk of damage to the deflection sheave and the main boom.

Always move the left-hand deflection sheave into the Transport position before setting down the MWL on the main boom. In this way you prevent the deflection sheave being pressed against the main boom when the MWL is set down, causing damage to both the deflection sheave and the main boom.

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MWL – Rigging and unrigging 5.3 Rigging work

Checking and correcting the end position Folded in Before setting down, both gantry masts must be folded in completely so that the rear pendant links and the gantry masts fit into the proper rests when set down.

For this reason, setting down the MWL is only enabled when both gantry masts are in the end position Folded in. You can check and correct this end position as follows:

7 6 5 2

• Press the Fold in gantry mast pre-selection button.

When the button is pressed, the red diode in the button will light up.

• Check whether both green diodes for the end position Folded in light up in the Locking status indicator lamp.

If both indicator lamps flash in rotation, or one or both of the red diodes lights up, the end position has not been reached and you must correct the position as follows.

• Connect the hand-held control to the socket connection of the right-hand or left-hand derricking cylinder, depending on which gantry mast winch Connecting the hand-held control, p. 5 - 41. you want to lock;

à

• Press and hold the Direction button r.

• Also press the Right/up movement button. The gantry mast will be folded in.

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

5

• Hold the button until the end position Folded in has been reached and both green diodes light up in the Locking status indicator lamp.

• Check the correct end position of the other gantry mast in the same way.

To do this, connect the hand-held control to the socket of the other derricking cylinder.

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H

Before setting the boom down also check if the boom is at an angle smaller than 5°. Otherwise, you will not be able to set the MWL down.

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MWL – Rigging and unrigging 5.3 Rigging work

Setting down the MWL

9 8

• Press the MWL Raise/set down pre-selection button.

When the button is pressed, the red diode in the button will light up.

• Press and hold the Direction button r.

• Also press the Left/down movement button. The MWL will be set down.

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

2 4

As soon as the end position MWL raised 90° has been left, both diodes in the Locking status indicator lamp flash in rotation.

When the MWL has reached the 5° position, the setting down procedure is interrupted and the red diode flashes in the Locking status indicator lamp.

• Check whether the left-hand deflection sheave on the raising frame is in

S

the Transport position, and move it into the Transport position if necessary; p. 5 - 52.

à

Risk of damage to the deflection sheave and the main boom Always move the left-hand deflection sheave into the Transport position before setting down the MWL on the main boom. In this way you prevent the deflection sheave being pressed against the main boom when the MWL is set down, causing damage to both the deflection sheave and the main boom.

When the left-hand deflection sheave is in the Transport position, you can carry on setting down the MWL:

@

The red diode lights up in the F1 button.

• Press the F1 button once.

The red diode in the button goes out and the setting down procedure is enabled again.

• If you no longer require the hand-held control, unplug it from the socket; 27.09.2004

à p. 5 - 42.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.21 Positioning the guy ropes

G

Positioning/removing the guy ropes Slew the superstructure to the rear or to the side in order to position the guy ropes. When the superstructure is slewed to the front, you will not be able to reach the guy ropes from the ladder since they are located above the driver’s cab.

Risk of accidents from head sheaves falling down.

Do not on any account loosen the joint locks or the securing pins in order to position the guy rope. In this way you prevent the head sheaves from folding out to the side or swinging round and injuring you.

• Remove the linchpin and pull out the rope holding rods (1).

• Loosen the retaining pin and remove the locking pin (5).

• Fold back the retaining sheet (4) at the handle (3).

Now you must lay the guy rope around the head sheave (2). Have a second person operate the winch; Locking/unlocking the winch, p. 5 - 64, Winding/unwinding the winches, p. 5 - 65.

à à

Risk of slack rope on the winch drum.

When unreeling the winches, ensure that the slack rope falls downwards from the holder on the gantry mast. If the slack rope does not fall downwards, pull it upwards onto the head sheave. This prevents the guy rope from being damaged by the slack rope.

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S S

Risk of damage to the guy rope.

When positioning the guy rope, make sure that the rope line which is fastened to the fixed point of the winch is pointing forwards.

In this way you prevent the rope lines from crossing when the winch is turned, causing damage to them.

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MWL – Rigging and unrigging 5.3 Rigging work

• Unwind the winch and while doing so lead the guy rope (4) to the lateral head sheave (2). Take care that no slack rope develops on the winch drum.

• Unwind the winch so far that the rope loop (3) of the guy rope are under the head sheave (2).

• Ensure that the rope loop is not twisted. The rope line which is fastened to the fixed point (1) of the winch must point to the front.

• Lay the guy rope around the head sheave (2).

• Unwind the winch so far that the guy rope is position on the head sheave (2).

• Lock the winch.

• Swing forward the retaining sheet (4) at the handle (3).

• Fasten the retaining sheet with the pin (5).

• Secure the pin (5) using the retaining pin.

• Insert the rope holding rods (1) and secure them with the linch pin.

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Fasten the guy rope to the lateral head sheave on the other side in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

Removing the guy rope

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Slew the superstructure to the rear or to the side in order to remove the guy ropes. When the superstructure is slewed to the front, the driver’s cab is in the rigging range.

Risk of damage from swinging guy rope.

Always slew the superstructure to the rear or to the side in order to remove the guy ropes. In this way you prevent the swinging guy rope from damaging parts of the superstructure (e.g. the windshield).

Risk of accidents from head sheaves falling down.

Check whether the lateral head sheaves are secured before you remove the gantry masts. In this way you prevent the head sheaves from folding out to the side or swinging round and injuring you.

Risk of accidents from swinging guy rope.

After it is released, the guy rope swings to the gantry mast. For this reason, position the ladder as far from the lateral head sheaves as possible. In this way you prevent the guy rope from hitting the ladder.

• Remove the linchpin and pull out the rope holding rods (1).

• Loosen the retaining pin and remove the locking pin (5).

• Fold back the retaining sheet (4) at the handle (3).

Have a second person operate the winch for the following step; Locking/unlocking the winch, p. 5 - 64, Winding/unwinding the winches, p. 5 - 65.

à à

• Unwind the winch until you can remove the

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rope loop (6) from the head sheave (2).

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MWL – Rigging and unrigging 5.3 Rigging work

• Remove the rope loop from the head sheave (2). The guy rope swings to the rear, under the gantry mast.

• Swing forward the retaining sheet (4) at the handle (3).

• Fasten the retaining sheet with the pin (5).

• Secure the pin (5) using the retaining pin.

• Insert the rope holding rods (1) and secure them with the linch pin.

• Reposition the ladder so that you are as close to the gantry mask as possible.

• Wind up the winch and while doing so, guide the guy rope as it threads into the brackets (1).

• Unwind the winch so far that the guy rope is positioned on the head sheave (2).

• Lock the winch.

Release the guy rope from the lateral head sheave on the other side in the same way.

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5 - 63

MWL – Rigging and unrigging 5.3 Rigging work

Locking/unlocking the winch

When rigging, the hand-held control is used for operation. If the hand-held control is defective, you can also carry out the functions from the crane cab; p. 5 - 69.

à

• Connect the hand-held control to the socket connection of the right-hand or left-hand derricking cylinder, depending on which winch you want to Connecting the hand-held control, p. 5 - 41. lock or unlock;

à

P

• Start the crane engine by pressing Start.

? >

• Press the Lock/unlock auxiliary hoist pre-selection button.

Release the button as soon as the crane engine is running.

When the button is pressed, the red diode in the button will light up.

Locking the winch

• Press and hold the Direction button R. • Also press the Right/upper movement button and keep pressing it until the end position Locked is reached.

The Locking status indicator lamp shows the procedure:

2 5

– As soon as the end position Unlocked is left, both diodes flash in rotation.

– When the end position Unlocked is reached, the green diode lights up.

Unlocking the winch

• Press and hold the Direction button R. • Also press the Left/lower movement button and keep pressing it until the end position Locked is reached.

The Locking status indicator lamp shows the procedure:

– As soon as the end position Locked is left, both diodes flash.

– When the end position Unlocked is reached, the red diode lights up.

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MWL – Rigging and unrigging 5.3 Rigging work

Winding/unwinding the winches

When rigging, the hand-held control is used for operation. If the hand-held control is defective, you can also carry out the functions from the crane cab; p. 5 - 69.

à

• Connect the hand-held control to the socket connection of the right-hand or left-hand derricking cylinder, depending on which winch you want to Connecting the hand-held control, p. 5 - 41. wind or unwind;

à

P

• Start the crane engine by pressing Start.

= <

• Press the Wind/unwind winch pre-selection button.

5 4

Release the button as soon as the crane engine is running.

• When the button is pressed, the red diode in the button will light up.

The winch must be unlocked for winding and unwinding. The Locking status indicator lamp shows the currect status: – When the green diode lights up, the winch is locked, and you must unlock p. 5 - 73. the winch;

à

– When the red diode lights up, the winch is unlocked and you can wind or unwind.

Winding the winch

• Press and hold the Direction button r.

• Also press the Right/up movement button. The winch will wind up.

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

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

Unwind the winch

• Press and hold the Direction button r.

• Also press the Left/down movement button. The winch will be unwound.

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

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The movement will continue until you let go of one of the two buttons.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.22

Securing/releasing the lateral head sheaves The lateral head sheaves are integrated in such a way that they can move longways and crossways; this means that they can move into an optimal position for the rope angle during operation. To remove the guy ropes, and for transport, the head sheaves are secured in a particular position.

Securing

When unrigging, you must secure the lateral head sheaves before you release the guy ropes.

• Release the linch pin and remove the locking pin (7) from the bracket (5).

• Position the head sheave so that the connection points (6) align.

• Insert the locking pin (7) into the connection points (6) and secure it with the linch pin.

• Position the head sheave by winding or unwinding the winch so that the bracket (6) is aligned with the bore hole in the retaining sheet (4).

• Remove the linch pin from the locking pin (1).

• Hold the securing pin (3) steady and pull the locking pins (1) out of the bracket (2).

• Remove the securing pin (3) from the bracket (2).

• Push the securing pin (3) through the bore hole in the retaining sheet (4) and into the bracket (5).

• Secure the securing pin with the locking pin (1) and the linch pin.

• Secure the lateral head sheave on the other

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side in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

Releasing

G S

When rigging, you must release the lateral head sheaves once the guy ropes are positioned.

Risk of accidents from head sheaves falling down.

Make sure that the guy ropes are positioned and slightly tightened before you release the lateral head sheaves.

In this way you prevent the head sheaves from folding out to the side or swinging round and injuring you.

Be careful not to damage the securing pins.

When releasing the securing pin, only wind up the winch until the guy rope is slightly taut. If you continue to wind up the winch after this, the securing pin may become subject to excessive load and be damaged.

• Position the head sheave by winding or unwinding the winch so that the securing pin (2) is released.

• Release the linch pin and remove the locking pin (1) from the bracket (5).

• Pull the securing pin (3) out of the bracket (4) and the bore hole in the retaining sheet (5).

• Fasten the securing pins (3) in the bracket (2) with the locking pins (1).

• Secure the locking pin (1) with the linch pin .

• Release the linch pin and remove the locking pin (7) from the bracket (6).

• Insert the locking pin (7) into the bracket (5).

• Secure the locking pin (7) with the linch pin.

• Release the lateral head sheave on the other

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side in the same way.

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MWL – Rigging and unrigging 5.3 Rigging work

5.3.23

G

Transporting the MWL Risk of accidents from securing incorrectly.

Always secure the MWL for transport by lashing it with suitable belts or chains. In this way you prevent the MWL from slipping during transportation and protruding from the vehicle edges, or falling off.

• Always secure the MWL on the separate vehicle with suitable belts or chains, attaching them on both sides to the connection eyes (1) provided for that purpose.

• Before transportation or raising from the storage location, check the following: – The turnbuckles (2) of the rear pendant links are in the Transport position; p. 5 - 50.

à

– The tension ratchets (3) are in the Transport position;

à p. 5 - 49.

– The hydraulic hoses and the electric cables are hung up in the bracket (4).

– The plugs of the electric cables are inserted in the dummy sockets (5).

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– All the pins are inserted in the corresponding holders and are secured.

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

5.4

Operation from the crane cabin during rigging When you use the hand-held control for operation during rigging, you will have a direct view of the points being rigged and thus be able to steer the movements required optimally, e.g. when locking the raising cylinders.

You can also steer all the movements required from the crane cab. To do this, however, you will require the assistance of a banksman since you will not be able to see all the rigging points from the crane cab.

The prerequisite for all movements is that there is an electrical connection p. 5 - 39) and a hydraulic connection ( p. 5 - 36) between the MWL ( and the main boom.

à

à

• Start the crane engine.

The crane engine can only be started from the crane cab when the bridging p. 5 - 42. plugs are inserted into all the sockets on the hand-held control;

à

5.4.1

In the submenu Rigging – MWL In order to fold in the gantry masts, you must open the submenu Operation – MWL ( p. 5 - 77).

All other movements which are necessary for rigging can be carried out from the submenu Rigging – MWL. This submenu can be opened from the Operation – MWL submenu in the Crane control display.

à

• If another menu is shown on the Crane control display, press the Exit submenu/entry mode button (

ö) until the main menu is displayed.

V

• In the main menu, press the button next to the Submenu Operation – MWL symbol.

• The Crane control display changes to the submenu Operation – MWL.

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

U

• In this submenu, press the button next to the symbol Submenu Rigging – MWL. The Crane control display switches to the submenu Rigging – MWL, and you can operate the following functions:

à p. 5 - 70 Locking the winches; à p. 5 - 73

– MWL Setting down;

–

– Unlocking the winches; p. 5 - 74

– Unwinding the winches; p. 5 - 75

à

– Winding the winches;

à

MWL – raising

à p. 5 - 71

– MWL Raising;

à p. 5 - 75

• Before raising, check that the following conditions are met: – The connections between the raising cylinders and the main boom have been established and the tension ratchets are secured in the Operation position; p. 5 - 45.

– The turnbuckles for the rear pendant links are in the Operation position; p. 5 - 52.

– The connections between the winches and the holding frame have p. 5 - 51. been broken;

à

à

S

à

Risk of damage from tension ratchets or turnbuckles which have not been loosened.

Make sure that the tension ratchets and the turnbuckles are in the Operation position before you raise the MWL. In this way you prevent the turnbuckles or tension ratchets from counteracting the raising, which could cause damage to these components, to the rear pendant links or to the raising cylinders.

• Press the button under the Raise MWL symbol (2). The MWL will be raised.

• Press and hold the button until the display MWL 5°/90° (1) shows the end position: – If the MWL exceeds the 5° position, the symbol p is shown in yellow.

– If the end position Raised to 90° has been reached, the symbol X is shown in green.

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

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

MWL – setting down

S S

• Before setting down, check that the following conditions are met: – – – –

The boom system is not braced.

The main boom is at an angle under 5°.

The lateral head sheaves are secured; p. 5 - 66.

The guy ropes have been removed from the lateral head sheaves; p. 5 - 60.

– The left-hand deflection sheave for the auxiliary hoist rope on the raisp. 5 - 53. ing frame is the the Transport position;

à

à

à

Risk of damage if the guy ropes are not removed.

Make sure that the guy ropes have been removed from the lateral head sheaves before setting down the MWL. In this way you prevent the securing pins from being put under excessive strain, which could also cause damage to the lateral head sheaves when the MWL is set down again.

Risk of damage to the deflection sheave and the main boom.

Always move the left-hand deflection sheave into the Transport position before setting down the MWL on the main boom. In this way you prevent the deflection sheave being pressed against the main boom when the MWL is set down, causing damage to both the deflection sheave and the main boom.

Before setting down, both gantry masts must be folded in completely so that the rear pendant links and the gantry masts fit into the proper rests when set down.

• Check whether the displays Left-hand/righthand gantry mast are showing the green symbol (1), (2) for the position Folded in.

Otherwise, the symbol Set down MWL (3) will be displayed in light grey and the button under the symbol will not be active.

In this case, you must move both gantry masts p. 5 - 77. into the end position Folded in;

à

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Now, the symbol Set down MWL (3) will be displayed in black and the button under the symbol will be active.

H

If the symbol is still displayed in light grey, check if the main boom is at an

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

angle less than 5°.

s

• Press the button under the Set down MWL symbol (2). The MWL will be set down.

As soon as the MWL leaves the Raised to 90° position, the symbol (1) will be shown in yellow.

When the MWL reaches the 5° position, the setting down procedure will be interrupted.

The Set down MWL symbol (2) goes out and the Control symbol (3) will be displayed.

The button under the symbol is now disabled.

• Check whether the left-hand deflection sheave on the raising frame is in the Transport position, and move it into the Transport position if necessary; p. 5 - 52.

à

S

Risk of damage to the deflection sheave and the main boom Always move the left-hand deflection sheave into the Transport position before setting down the MWL on the main boom. In this way you prevent the deflection sheave being pressed against the main boom when the MWL is set down, causing damage to both the deflection sheave and the main boom.

When the left-hand deflection sheave is in the Transport position, you can carry on setting down the MWL:

• Press the Confirm entry button (Ö) once.

The Control symbol (3) goes out and the Set down MWL symbol (2) will be displayed.

Press and hold the button under the symbol Set down MWL (2) until the end position Set down has been reached: – If the MWL is under the 5° position, the symbol (1) is shown in green.

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– When the end position Set down has been reached, the movement is stopped mechanically.

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

Locking the winches

ab

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

Otherwise, the symbols Unlock left-hand winch and Unlock right-hand winch will be displayed in light grey and the buttons next to the symbols will not be active.

• Press the button next to the symbol Unlock left-hand winch (3) or Unlock right-hand winch (4) depending on which winch you want to unlock.

• Press and hold the button until the corresponding display Left-hand/Right-hand winch lock (1), (2) shows the end state: – While the unlocking procedure is being carried out, the symbol Locked a or b will be displayed in yellow.

– When the end position Unlocked has been reached, the corresponding symbol (1), (2) will be displayed in green.

If the purple symbol c or d is displayed, indiTroubleshooting, p. 10 - 3. cating an error;

à

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

Unlocking the winches

This section describes how to unlock the winches during rigging. For information about unlocking the winches with a braced boom system; Derricking to the bracing angle, p. 6 - 17.

à

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

ef

H

Otherwise, the symbols Unlock left-hand winch and Unlock right-hand winch will be displayed in light grey and the buttons next to the symbols will not be active.

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

• Press the button next to the symbol Unlock left-hand winch (3) or Unlock right-hand winch (4) depending on which winch you want to unlock.

• Press and hold the button until the corresponding display Left-hand/Right-hand winch lock (1), (2) shows the end state: – While the unlocking procedure is being carried out, the symbol Lockeda or b will be displayed in yellow.

– When the end position Unlocked has been reached, the corresponding symbol (1), (2) will be displayed in red.

If the purple symbol c or d is displayed, indiTroubleshooting, p. 10 - 3. cating an error;

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à

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

Winding/unwinding the winches

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

When the displays Left-hand/Right-hand winch lock show the green symbol (1), (2) for the position Locked, the corresponding symbols will be displayed in light grey: – For winding and unwinding the left-hand winch, the symbols (3) and (5) – For winding and unwinding the right-hand winch, the symbols (4) and (6).

The buttons next to these symbols are not active.

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

à p. 5 - 73.

When the displays Left-hand/Right-hand winch lock show the red symbol (1), (2) for the position Unlocked, the corresponding symbols will be displayed in black and the buttons next to the symbols will be active: – Wind the left-hand winch (3) – Unwind the left-hand winch (5) – Wind the right-hand winch (4) – Unwind the right-hand winch (6).

• Press the button next to the symbol for the movement required.

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

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

5.4.2

In the submenu Operation – MWL Normally, you do not need to switch to the submenu Operation - MWL when rigging. However, if both gantry masts are not in the end position Folded in before setting down the MWL, you must switch to the submenu Operation MWL in order to correct this position.

When the submenu Rigging – MWL is opened:

• Press the button next to the symbol Submenu Operation – MWL (1).

If the Crane control display shows another menu:

• Press the button Exit submenu/input mode (ö) as many times as necessary until the main menu is displayed.

• In the main menu, press the button next to the symbol Submenu Operation – MWL (1).

The Crane control display changes to the submenu Operation – MWL.

V

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MWL – Rigging and unrigging 5.4 Operation from the crane cabin during rigging

Folding in the gantry masts

H

This section only describes how to fold in the gantry masts during rigging.

Folding the gantry masts in and out when the main boom is raised and telescoped out, and all other types of operation, are described in the chapters Operation with the MWL and main boom, luffing jib and so on, since some of the prerequisites differ in each case.

Folding in the gantry mast is only enabled when the current rope forces in the guy ropes are under the maximum permissible rope force. When rigging, however, this prerequisite is always fulfilled since the guy ropes have already been removed from the lateral head sheaves.

If a gantry mast is not in the end position Folded in, the corresponding display Left-hand/ Right-hand gantry mast will show the symbol (1), (2) in yellow.

• Press the button next to the corresponding symbol: – Fold in the left-hand gantry mast (3), or – Fold in the right-hand gantry mast (4).

• Hold down the button until the corresponding display Left-hand/right-hand gantry mast shows the symbol (1), (2) in green.

If the purple symbol l or n is displayed, indiTroubleshooting, p. 10 - 3. cating an error;

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à

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6 6

Operation with the main boom and the MWL

6.1

Further rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

6.1.1 6.1.2 6.1.3 6.1.4 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.3 6.3.1 6.3.2 6.4 6.4.1 6.4.2 6.5

6666-

2 3 4 6

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

9

CHECKLIST: Bringing the boom system into the operating condition . . . . . . .

CHECKLIST: Bringing the boom system into the rigging mode . . . . . . . . . . . .

Setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening the submenu Operation – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telescoping with rigged MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Folding the gantry masts out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brace the boom system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locking/unlocking the winches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66666666-

9 10 11 13 14 15 17 19

Operation with MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21 Bringing the boom system into the operating condition . . . . . . . . . . . . . . . . . . 6 - 21 Bringing the boom system into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . 6 - 23 Operation with unbraced boom system and raised MWL. . . . . . . . . . . . . . . . . . . 6 - 25 Bringing the boom system into the operating condition . . . . . . . . . . . . . . . . . . 6 - 25 Bringing the boom system into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . 6 - 27 Driving with rigged truck crane and rigged MWL . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29 Rigging modes for moving and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 30 Driving the rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 32

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6.5.1 6.5.2 6.5.3

CHECKLIST: Rigging for operation with main boom . . . . . . . . . . . . . . . . . . . . .

CHECKLIST: Unrigging after operation with the main boom. . . . . . . . . . . . . . .

Installing/removing the three-part rope holding rod . . . . . . . . . . . . . . . . . . . . .

Reeving the hoist rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Operation with the main boom and the MWL

6

Operation with the main boom and the MWL

G

Risk of accidents if the safety information is ignored.

When operating the main boom with the MWL, all the warnings given in the GMK 7450 operating instructions apply without exception.

This chapter merely supplements the GMK 7450 operating instructions through the addition of information necessary when operating the main boom together with the MWL.

In the following sections there is information on the further procedure for operating with the main boom and the MWL after the MWL has been rigged.

– The section Further rigging work contains information on further rigging work specifically for operation with the main boom and the MWL, and on preparations for unrigging.

– The section Operation with braced boom system contains all the information required to set the SLI, telescope with rigged MWL and to fold the MWL in and out and brace it.

– The section Operation with MWL set down contains all the information required to operate with the main boom when the MWL is rigged but neither raised nor braced.

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

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

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6-1

Operation with the main boom and the MWL 6.1 Further rigging work

6.1

Further rigging work

6.1.1

CHECKLIST: Rigging for operation with main boom

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.

1. The MWL was rigged in accordance with the chapter MWL – Rigging and unrigging; CHECKLIST: Rigging the MWL, p. 5 - 5.

à

1100

2. The current rigging mode for operation with the main boom is entered on the SLI.

3. Reeve the hoist rope on the hoist gear required for the job planned; Reeving the hoist rope, p. 6 - 6.

à

4. If necessary, install the lifting limit switch and lay the lifting limit switch weight around the hoist rope; GMK 7450 Operating instructions – mounting the lifting limit switch.

GMK 7450 Operating instructions – mounting/dismantling the lifting limit switch.

à à

5. Install anemometer and also air traffic control light with additional equipment; GMK 7450 Operating instructions – mounting/dismantling the anemometer.

GMK 7450 Operating instructions – mounting/dismantling the air traffic control light.

à à

Bring the boom system into the operating condition required:

– For operation with MWL set down;

à p. 6 - 9

à p. 6 - 21

– For operation with unbraced boom system and raised MWL; p. 6 - 25.

à

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– For operation with braced boom system;

Operation with the main boom and the MWL 6.1 Further rigging work

6.1.2

CHECKLIST: Unrigging after operation with the main boom

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.

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

à p. 6 - 10

à p. 6 - 23

– After operation with unbraced boom system and raised MWL; p. 6 - 27.

à

1100

2. The current rigging mode for operation with the main boom is entered on the SLI.

3. Install anemometer and also air traffic control light with additional equipment; GMK 7450 Operating instructions - mounting/dismantling the anemometer.

GMK 7450 Operating instructions - mounting/dismantling the air traffic control light.

à à

4. Remove the lifting limit switch weight from the hoist rope and remove the lifting limit switch as applicable; GMK 7450 Operating instructions - mounting/dismantling the lifting limit switch weight.

GMK 7450 Operating instructions - mounting/dismantling the lifting limit switch.

à à

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5. Unreeve the hoist rope.

6. To continue unrigging the MWL; p. 5 - 10.

MWL Operating instructions GMK 7450

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à CHECKLIST: MWL – unrigging,

6-3

Operation with the main boom and the MWL 6.1 Further rigging work

6.1.3

Installing/removing the three-part rope holding rod A three-part rope holding rod is supplied with the MWL. The rope holding rod consists of two short rods (1) with pegs which can be inserted into a long rod (2).

For operation with the MWL and the main boom, you must install the rope holding rod.

For jobs to be done without the MWL, the three-part rope holding rod can stay installed.

Installing

You must install the three-part rope holding rod before installing the lateral rope sheaves. Otherwise you will not be able to pull out the continuous rope holding rod.

• Loosen the retaining pin and pull out the continuous rope holding rod (3).

• Pull the spring cotters out of the short rods (1).

• Push the short rods (1) from the centre out through the retaining sheets (2) and place them on the bore holes in the retaining sheets, together with the pegs.

• Hold the long rod (3) between the retaining sheets (2) and push the short rods (1) into the recesses (4) in the long rod with the pegs.

• Secure both short rods (1) with the spring

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cotters.

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.1 Further rigging work

Removal

You must remove the three-part rope holding rod in order to reeve the hoist rope. It is possible to remove it with the lateral head sheaves installed. If you want to use the continuous rope holding rod after removal, you must remove the lateral head sheaves first.

• Pull the spring cotters out of the short rods (1).

• Hold the long rod (3) firm.

• Push the short rods (1) outwards and place them on the bore holes in the retaining sheets (2) with the pegs.

• Put down the long rod (3).

• Pull the short rods (1) through the retaining sheets (3).

• Insert the spring cotters in the short rods (1) and set them down.

• If necessary, push the continuous rope hold-

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ing rod (4) into the boom head and secure it with the retaining pins.

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6-5

Operation with the main boom and the MWL 6.1 Further rigging work

6.1.4

Reeving the hoist rope This section only describes the procedure for reeving with rigged MWL. To remove and set down the rope end fitting and to fasten the fork element, proceed exactly as described in the GMK 7450 operating instructions – Part 2 Crane operation.

Positioning hoist rope

The hoist ropes required are pulled to the front and are already positioned on the required raising frame deflection sheave.

Removing the rope holding rods

• Loosen the retaining pins and remove the rope holding rods (2) to (6) from the bore holes on the boom head.

• Remove the three-part rope holding rod (4);

à p. 6 - 5.

The procedure for positioning the hoist ropes depends on the number of sheaves on the main boom head.

For standard equipment with 9 sheaves To position the main hoist rope:

• Lead the main hoist rope (3) down over the right-hand head sheave (1).

• When reeving, begin with the sheave furthest to the outside (2).

To position the auxiliary hoist rope:

• Lead the auxiliary hoist rope (4) down over the left-hand head sheave (6). thest to the outside (5).

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MWL Operating instructions GMK 7450

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• When reeving, begin with the sheave fur-

Operation with the main boom and the MWL 6.1 Further rigging work

For standard equipment with 11 sheaves To position the main hoist rope:

• Lead the main hoist rope (3) down over the right-hand head sheave (1).

• When reeving, begin with the sheave (2) next to the retaining sheet.

To position the auxiliary hoist rope:

• Lead the auxiliary hoist rope (4) down over the left-hand head sheave (6).

• When reeving, begin with the sheave (5) next to the retaining sheet.

For standard equipment with 13 sheaves To position the main hoist rope:

• Lead the main hoist rope (3) down over the inner, right-hand head sheave (1).

• When reeving, begin with the sheave (2) next to the retaining sheet.

To position the auxiliary hoist rope:

• Lead the auxiliary hoist rope (4) down over the inner, left-hand head sheave (6).

• When reeving, begin with the sheave (5) next to the retaining sheet.

Reeving the hoist rope

• Reeve the hoist rope in such a way that the rope lines are distributed

à

GMK 7450 operating instructions – Part 2 Crane operation – Rigging evenly; work – Possible reevings on the main boom head.

• Attach the rope end fitting and fasten it to the fixed point; à GMK 7450 – Part 2 Crane operation – Rigging work.

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6-7

Operation with the main boom and the MWL 6.1 Further rigging work

Installing the rope holding rods After reeving the hoist rope you must install the rope holding rods again.

The upper rope holding rods are inserted differently for operation with the MWL than for operation without the MWL.

S

Risk of damage to the hoist rope!

Before operation with the MWL, always check if the upper rope holding rods (2) and (3) are inserted into the front bore holes (7).

If the rope safety rods are inserted into the rear bore holes, the hoist rope runs at an impermissible angle and could cause damage, causing the load to fall.

• Insert the rope retaining rods (2) and (3) into the front bore holes in the sheets (7).

• Secure the rope holding rods (2) and (3) into place using the retaining pins.

• Insert the rope holding rods (4) to (6) through the bore holes on the main boom head.

• Secure the rope holding rods (4) to (6) using the retaining pins.

• Install the three-part rope holding rod (1);

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à p. 6 - 4.

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.2 Operation with braced boom system

6.2

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

For operation with rigged but unraised MWL; down, p. 6 - 21.

à Operation with MWL set

For operation with raised MWL but unbraced boom system; with unbraced boom system and raised MWL, p. 6 - 25.

6.2.1

à Operation

CHECKLIST: Bringing the boom system into the operating condition

H 1100

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.

1. Select the actual rigging mode for operation with main boom and MWL on the SLI, or set the respective SLI code according to the Lifting capacity table; Setting the SLI, p. 6 - 11.

à

2. Telescope the main boom out to the telescoping required for operation according to the Lifting capacity table; Telescoping with rigged MWL, p. 6 - 14.

à

3. Fold out both gantry masts;

à Folding the gantry masts out/in, p. 6 - 15.

4. Derrick the main boom to the bracing angle required and brace the Brace the boom system, p. 6 - 17. boom system;

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à

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6-9

Operation with the main boom and the MWL 6.2 Operation with braced boom system

6.2.2

CHECKLIST: Bringing the boom system into the rigging mode

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.

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

1100

2. The current rigging mode for operation with the main boom and MWL Setting the SLI, p. 6 - 11. is entered on the SLI;

à

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

4. To unlock the MWL, derrick the main boom to the bracing angle; Derricking to the bracing angle, p. 6 - 17.

à

à Folding the gantry masts out/in, p. 6 - 15.

Retract the main boom completely; à Telescoping with rigged MWL,

5. Fold in the gantry masts; 6.

p. 6 - 14.

7. Slew the superstructure into the position for unrigging (preferably to the rear) and lower the main boom to the horizontal.

à CHECKLIST: Unrigging after opera-

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8. To continue unrigging the MWL; tion with the main boom, p. 6 - 3.

6 - 10

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.2 Operation with braced boom system

6.2.3

Setting the SLI On the SLI, a truck crane rigging mode for main boom operation which is also permissible for operation with the MWL is entered first (Entering the Operating instructions GMK 7450 – Part 2 Crane operation – rigging mode Crane operation).

In conclusion, the MWL is entered for this rigging mode.

à

The submenu Enter rigging mode shows the rigging mode entered, e.g.: – Counterweight version 120 t – Main boom operation – Outrigger span 8.76 x 8.90 m (28.7 x 29.2 ft) – ±180° slewing range.

The SLI code display (3) shows the corresponding SLI code, e.g. 1160.

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

• Press the button beside the symbol Enter MWL (2) once. The button next to the symbol is only active when the MWL is in the Raised to 90° position.

H

If it is not permissible to operate the MWL with the rigging mode shown, there will be no change on the display.

If operation with the MWL is permissible with the rigging mode shown:

120 t

– The symbol Enter MWL (2) is highlighted in green – The Current boom system display (1) shows a truck crane with main boom and MWL – The SLI code display (3) shows the corresponding SLI code for operation with MWL, e.g. 3160.

• Accept the rigging mode selected (2x Ö ).

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3160

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6 - 11

Operation with the main boom and the MWL 6.2 Operation with braced boom system

The submenu SLI monitoring now shows the selected rigging mode with MWL. The Maximum load display (1) shows the load of the rigging curve for the current rigging mode according to the Lifting capacity table, e.g.

5.0 t (11 000 lbs).

The SLI will only enable the increased lifting capacity for operation with MWL when the MWL is braced.

à Malfunctions on the

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If error messages occur; SLI, p. 10 - 7.

6 - 12

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.2 Operation with braced boom system

6.2.4

Opening the submenu Operation – MWL The submenu Operation – MWL contains all the operating elements you need to bring the MWL into the operating condition or rigging mode.

Depending on what is currently shown on the Crane control, you can open the submenu Operation – MWL in various ways.

When the submenu Rigging – MWL is opened:

• Press the button next to the symbol Submenu Operation – MWL (1).

If the Crane control display shows another menu:

• Press the button Exit submenu/input mode (ö) as many times as necessary until the main menu is displayed.

• In the main menu, press the button next to the symbol Submenu Operation – MWL (1).

The Crane control display changes to the submenu Operation – MWL.

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6 - 13

Operation with the main boom and the MWL 6.2 Operation with braced boom system

6.2.5

Telescoping with rigged MWL

G Prerequisites

When telescoping with rigged MWL, the telescoping speed is limited to 70% and high-speed mode is blocked. When telescoping, the winches follow it automatically so that the force in the guy ropes stays as constant as possible. When telescoping begins, and at high telescoping speeds, the rope force may fluctuate slightly at first until it settles at a constant value.

Danger from slack rope.

When telescoping, pay attention to the guy ropes. If they sag significantly, there is a malfunction. In this case, interrupt telescoping and wind up the Winding/unwinding the winches, winch until the guy ropes are taut ( p. 5 - 75).

In this way you prevent slack rope forming on the winches.

à

The following prerequisites must be fulfilled for telescoping:

NO ef Telescoping

– Both gantry masts are folded in. Both symbols for the end position Folded in are shown in green; Folding the gantry masts out/in, p. 6 - 15.

à

– Both winches are unlocked. On the displays Left-hand/Right-hand winch lock, the Unlocked symbols are shown in red; Locking/unlocking the winches, p. 6 - 19.

à

For telescoping with rigged MWL, you can use either fully automatic (teleautomation) or semi-automatic operation.

With full automation Telescoping with full automation is possible directly from the submenu Operation – MWL. xx.x t

xx.x t

+xx.x ° +xx.x °

The button under the display Enter teleautomation set value (2) and the displays for telescoping (1) have the same function as in the submenu Telescoping.

With semi-automation

• Switch to the main menu by using the Exit

Telescoping takes place in the same way as for operation without MWL.

6 - 14

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MWL Operating instructions GMK 7450

27.09.2004

submenu/input mode button (3) and from there switch to the Telescoping submenu.

Operation with the main boom and the MWL 6.2 Operation with braced boom system

6.2.6

Folding the gantry masts out/in Before you can raise a load, you must fold out both gantry masts into the end position and brace the boom system.

It is not possible to raise loads at other gantry mast positions, e.g. folded in.

Folding the gantry masts in and out is carried out in the Crane control display, Opening the in the submenu Operation – MWL. If another menu is open; submenu Operation – MWL, p. 6 - 13.

à

Prerequisites

Folding the gantry masts in and out is only enabled when the following prerequisites are fulfilled:

R X

– The boom system is not braced, the symbol on the Bracing status display will be shown in grey.

– The MWL is raised to 90°, on the display MWL 5°/90° the green symbol is shown.

– There is no load raised other than the hook block.

Folding in/folding out

When all the prerequisites are fulfilled, folding in and out is enabled.

The following symbols are shown in black: – Fold in the left-hand gantry mast (1) – Fold out the left-hand gantry mast (3) – Fold in the right-hand gantry mast (2) – Fold out the right-hand gantry mast (4) The buttons next to the symbols are active.

As soon as any of the prerequisites fails to be fulfilled, the symbols are shown in light grey.

The buttons next to the symbols are not active.

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6 - 15

Operation with the main boom and the MWL 6.2 Operation with braced boom system

• Press and hold the button for the movement required next to the symbol (3), (4), (5) or (8).

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

In this case, you must unlock the winch; Unlock winches, p. 6 - 20. The movement will then be enabled again.

à

The folding procedure is started, and the symbol Intermediate position (L M) will be shown in yellow on the corresponding displays Lefthand/right-hand gantry mask (6), (7).

The value on the display Current rope force (1), (2) changes correspondingly.

• Hold down the button required next to the symbol (3), (4), (5) or (8) until the corresponding display Left-hand/right-hand gantry mast (6), (7) shows the end position: – When the end position Folded in is reached, the symbol Folded in (N O) is shown in green.

– When the end position Folded out is reached, the symbol Folded out (P Q) is shown in green.

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

If the symbol (l n) is shown in purple, there Malfunctions during operation is an error; with the MWL, p. 10 - 3.

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à

6 - 16

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.2 Operation with braced boom system

6.2.7

Brace the boom system Bracing the boom system is carried out in the Crane control display, in the Opening the subsubmenu Operation – MWL. If another menu is open; menu Operation – MWL, p. 6 - 13.

à

Prerequisites

The following conditions must be fulfilled before bracing the boom system:

X

– The MWL is raised to the end position 90°. The green symbol is shown on the display MWL 5°/90°.

– All conditions of the telescoping mechanism for bracing the boom system are fulfilled (telescopic sections locked, telescoping cylinder locked, telescopic section set down).

The symbol (1) on the display Telescoping mechanism status is displayed in green.

– The main boom is at a telescoping which is permissible for operation with the MWL according to the Lifting capacity table.

PQ

– Both gantry masts are folded out. Both symbols for the end position Folded out are shown in green.

– The corresponding SLI code for the operation planned with the MWL is entered.

Derricking to the bracing angle

In addition to the prerequisites stated, the main boom must be at a particular angle; this is known as the bracing angle. The bracing angle is derived from the entered SLI code.

The display Bracing angle set value (4) shows the required bracing angle, e.g. 77°.

If the main boom is at another angle, the symbol in the Bracing angle (1) display and the symbol Boom system bracing (2) will be shown in grey.

• Raise the main boom to the bracing angle.

The display Current main boom angle (3) must also show the bracing angle, e.g. 77°.

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The symbol will now be shown on the Bracing angle display (1) in green.

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6 - 17

Operation with the main boom and the MWL 6.2 Operation with braced boom system

Bracing

When the prerequisites stated are fulfilled and the main boom is at the bracing angle, bracing is enabled.

T

The symbol Boom system bracing is now shown in black and the button next to the symbol is active.

• Press and hold the button next to the symbol Boom system bracing (4) until the boom system is braced.

You can follow the bracing procedure: – The winches will be wound up. The values in the displays Current rope force (5), (6) increase until a preset rope force is reached.

– The winches are unwound to a certain angle, and locked (the guy ropes can now be slightly slack).

– The displays Left-hand/Right-hand winch lock (1), (2) show the Locked symbols in green.

– The symbol in the Bracing status display (3) is shown in green.

The boom system is now braced.

With braced boom system, only the function Unlock winches is enabled. The symbol (3) is shown in black and the button next to the symbol is active.

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All other functions are disabled. The symbols (1), (2) and (4) to (7) will be shown in light grey and the buttons next to the symbols are inactive.

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.2 Operation with braced boom system

The SLI now enables the increased lifting capacity and the display Maximum load (1) shows the corresponding value in accordance with the lifting capacity table.

6.2.8

Locking/unlocking the winches Locking and unlocking both winches simultaneously is carried out in the Crane control display, in the submenu Operation – MWL. If another menu is Opening the submenu Operation – MWL, p. 6 - 13. open;

à

Lock winches

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

F

When the boom system is braced, the symbol Lock winches appears in light grey and the button next to the symbol is inactive.

F

In this case, you must unbrace the boom system. When the boom system is not braced, the symbol Lock winches appears in black and the button next to the symbol is active. To unbrace the boom system, you must unlock the p. 6 - 20. winches;

à

• Press the button next to the Lock winches symbol (1).

• Press and hold the button until the displays Left-hand/Right-hand winch lock (2), (3) show the end state: – While the locking procedure is being carried out, the symbols Unlocked (e f) are displayed in yellow.

– When the end state Locked is reached, the symbols Locked (a b) are displayed in green.

If the purple symbol or is displayed, indicating Malfunctions during operation with an error; the MWL, p. 10 - 3.

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à

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Operation with the main boom and the MWL 6.2 Operation with braced boom system

Unlock winches

G

H

When the boom system is braced, it is only possible to unlock the winches Derricking to after the main boom has been raised to the bracing angle; the bracing angle, p. 6 - 17.

à

Otherwise, the symbol Unlock winches will be shown in light grey and the button next to the symbol is inactive.

When you press the button to unlock the winches, the guy ropes will be first be wound in slightly in order to relieve the locking units of pressure.

• Press the button next to the symbol Unlock winches (4).

• Press and hold the button until the displays Left-hand/Right-hand winch lock (1), (2) show the end state: – While the locking procedure is being carried out, the symbols Unlocked(e f) are displayed in yellow.

– When the end state Unlocked is reached, the symbols Unlocked (e f) are displayed in red.

If the purple symbol c or d is displayed, indiMalfunctions during operacating an error; tion with the MWL, p. 10 - 3.

à

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If the boom system had previously been braced, it is now unbraced and the symbol in the Bracing status display (3) will be shown in grey.

6 - 20

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.3 Operation with MWL set down

6.3

Operation with MWL set down This section only describes operation with the main boom and MWL set down. The boom system is not braced and increased lifting capacity will not be enabled.

S 6.3.1

Risk of damage to the hoist rope!

When the MWL is set down, only operation with the main hoist is permitted. If the main hoist is led over the right-hand rope sheave on the raising frame, the hoist rope runs at an impermissible angle and could cause damage, causing the load to fall.

Bringing the boom system into the operating condition This section presumes that the MWL is rigged as described in the checklist Rigging the MWL for operation with MWL set down.

If previously operated with the boom system braced, check that the following conditions are met.

– The guy ropes are removed from the lateral head sheaves and are lying, lightly taut, on the brackets on the gantry masts; Removing the guy rope, p. 5 - 62.

à

– The MWL is set down on the main boom;

à MWL – setting down, p. 5 - 71.

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6 - 21

Operation with the main boom and the MWL 6.3 Operation with MWL set down

Setting the SLI

For operation with the MWL set down, you must enter the current rigging mode for operation with the main boom without MWL on the SLI.

H

If you select operation with MWL, a maximum load capacity of only ca. 5.0 t (11 000 lbs) will be enabled.

• Enter the current rigging mode.

For operation with MWL set down: – The Current boom system display (1) must shown a truck crane without MWL – The SLI code display (3) must show an SLI code for operation with the main boom, e.g. 1160.

• Accept the rigging mode selected (2x Ö ).

The symbol Input MWL (2) is shown in light grey when the MWL is set down and the button next to the symbol is not active.

The SLI now takes into account the Lifting capacity table corresponding to the SLI code displayed for operation with the main boom.

When the MWL is set down, the values specified in the Lifting capacity tables are reduced.

The decreased values are shown directly in the Maximum load display (1).

1160

To calculate these values for operations planning, there are corresponding formulas and examples in the Lifting capacity tables in the chapter Notes.

120 t

If error messages occur;

6 - 22

à Malfunctions on the SLI, p. 10 - 7.

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MWL Operating instructions GMK 7450

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H

The display Maximum load (1) only shows the reduced values when the MWL is connected electrically. Otherwise, the values from the lifting capacity tables will be shown – however, the reduced values still apply for shutdown of the system.

Operation with the main boom and the MWL 6.3 Operation with MWL set down

Telescoping

G

Telescoping with the MWL set down is carried out in the same way as for operation with the main boom.

Risk of damage to the lateral head sheaves and the guy ropes.

Make sure that the guy ropes have been removed from the lateral head sheaves before telescoping the main boom with the MWL set down. In this way you prevent damage to the lateral head sheaves or the guy ropes during telescoping.

Derricking

When the MWL is set down, derricking is only released when the MWL is set down to a point that the display MWL 5°/90° shows the symbol (1) Placed under 5°. Otherwise derricking is blocked and the arrows (2) in the Derricking gear display are shown in red.

Operation with the main boom

Operation of the power units when working with the main boom with the MWL set down is the same as for working with the main boom without Operating instructions GMK 7450 – Part 2 Crane operation – Crane opMWL; eration.

6.3.2

à

Bringing the boom system into the rigging mode Operation of the power units with the MWL set down is the same as for Operating instructions working with the main boom without MWL; GMK 7450 – Part 2 Crane operation – Crane operation.

à

This section presumes that – the truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal.

– the actual rigging mode for operation with the main boom is entered on the SLI.

• Set down the load.

• Fully retract the main boom.

• Slew the superstructure into the position for unrigging (preferably to the 27.09.2004

rear) and lower the main boom to the horizontal.

To continue unrigging the MWL; with the main boom, p. 6 - 3.

MWL Operating instructions GMK 7450

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à CHECKLIST: Unrigging after operation

6 - 23

Operation with the main boom and the MWL 6.3 Operation with MWL set down

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Blank page

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.4 Operation with unbraced boom system and raised MWL

6.4

Operation with unbraced boom system and raised MWL This section only describes operation with the main boom and raised MWL. The boom system is not braced and increased lifting capacity will not be enabled.

6.4.1

Bringing the boom system into the operating condition This section presumes that the MWL is rigged as described in the checklist Rigging the MWL.

Setting the SLI

For operation with raised MWL and unbraced boom system, you must enter the current rigging mode for main boom operation with MWL on the SLI; Setting the SLI, p. 6 - 11.

à

The submenu SLI monitoring now shows the selected rigging mode with MWL. In this operating condition, the maximum permissible load is limited to the rigging program.

The Maximum load display (1) shows the load of the rigging curve for the current rigging mode according to the Lifting capacity table, e.g.

5.0 t (11 000 lbs).

Higher loads will not be enabled since the boom system is not braced.

If error messages occur; SLI, p. 10 - 7.

à Malfunctions on the

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Operation with the main boom and the MWL 6.4 Operation with unbraced boom system and raised MWL

Telescoping

G

For telescoping, the same prerequisites and notes apply as for telescoping with the boom system braced.

Danger from slack rope.

When telescoping, pay attention to the guy ropes. If they sag significantly, there is a malfunction. In this case, interrupt telescoping and wind up the Winding/unwinding the winches, winch until the guy ropes are taut ( p. 5 - 75).

In this way you prevent slack rope forming on the winches.

à

When telescoping, proceed exactly as for telescoping with braced boom p. 6 - 14. system;

à

Derricking

When the MWL is raised, derricking is only released when the MWL is raised to a point that the display MWL 5°/90° shows the symbol Raised to 90° (1).

Otherwise derricking is blocked and the arrows (2) in the Derricking gear display are shown in red.

Operation with the main boom

Operation of the power units when working with the main boom and raised OpMWL is the same as for working with the main boom without MWL; erating instructions GMK 7450 – Part 2 Crane operation – Crane operation.

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à

6 - 26

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.4 Operation with unbraced boom system and raised MWL

6.4.2

Bringing the boom system into the rigging mode Operation of the power units with raised MWL and unbraced boom system Operating is the same as for working with the main boom without MWL; instructions GMK 7450 – Part 2 Crane operation – Crane operation.

à

This section presumes that – the truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal and – the actual rigging mode for operation with the main boom is entered on the SLI.

• Set down the load.

• Fully retract the main boom.

• Slew the superstructure into the position for unrigging (preferably to the rear) and lower the main boom to the horizontal.

à CHECKLIST: Unrigging after operation

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To continue unrigging the MWL; with the main boom, p. 6 - 3.

MWL Operating instructions GMK 7450

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6 - 27

Operation with the main boom and the MWL 6.4 Operation with unbraced boom system and raised MWL

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Blank page

6 - 28

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.5 Driving with rigged truck crane and rigged MWL

6.5

Driving with rigged truck crane and rigged MWL This section describes how to drive the truck crane with an installed counterweight and rigged MWL.

H

G G G 6.5.1

When driving with rigged MWL, always switch on the separate steering and do not steer if stationary.

Risk of accidents.

You must not 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 brake must be engaged.

Risk of accidents when you cannot see the entire truck crane.

When moving the rigged truck crane, keep in contact with a banksman, either by sight or by means of radio, who can observe the parts of which you have no overview e.g. the erected boom when the superstructure is slewed to the rear).

This prevents accidents resulting from collisions with persons, other construction equipment, ledges of buildings, cables or other objects.

Driving route The route must be along 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 area of the tyres must be increased using packing made of a stable material (e.g. wooden planks).

à

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S

Risk of damage to tyres.

Check the pressure in the tyres before moving the rigged truck crane.

The truck crane may be moved only if tyre pressures are at the prescribed GMK 7450 operating instructions – Part 1 Driving – Technical data – levels; Tyres.

On no account should you reduce the tyre pressure!

MWL Operating instructions GMK 7450

2 084 909 en

6 - 29

Operation with the main boom and the MWL 6.5 Driving with rigged truck crane and rigged MWL

6.5.2

Rigging modes for moving and axle loads The rigged truck crane may only be moved under certain circumstances.

The boom must be moved to a specific position depending on the counterweight installed.

S G Bringing the truck crane into the rigging mode

Risk of damage to the axle lines!

Always move the main boom to the prescribed position before you drive the rigged truck crane. If the boom is not in the prescribed position or the counterweight version is too large, the axle lines will be submitted to loads in excess of those permitted.

Risk of accidents when SLI is overridden!

Always set the SLI code corresponding to the current rigging mode when you telescope 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 operates without overload protection when the SLI is overridden!

The tables on the following pages show the required rigging modes for driving with the MWL raised or set down. Before being moved, you have to bring the truck crane into the required rigging mode.

• Set down the load, with the exception of the hook block, which is given in the following table; no load may be lifted.

• Unrig the counterweight sections, if needed. It is only possible to unrig the counterweight with the truck crane itself when the MWL is set down: – If applicable, set down the MWL as well; p. 5 - 57.

à Setting down the MWL,

– Lower the counterweight onto the counterweight platform.

– Enter the rigging mode with 0 t counterweight for operation with main boom and without MWL on the SLI display; Setting the SLI, p. 6 - 22.

à

– Unrig the relevant counterweight sections.

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– Lock the remaining counterweight on the turntable.

6 - 30

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MWL Operating instructions GMK 7450

Operation with the main boom and the MWL 6.5 Driving with rigged truck crane and rigged MWL

• Set the rigging mode for the currently rigged counterweight combination

1100

on the SLI: – When the MWL is set down for operation with the main boom without Setting the SLI, p. 6 - 22.

MWL;

à

– When the MWL is raised for operation with the main boom and MWL; Setting the SLI, p. 6 - 11.

à

• Slew the superstructure into the working position 0° to the rear.

!

• Lock the superstructure. The Turntable locking status display must show the symbol for the Locked setting in green.

• Fully retract the main boom.

• Derrick the main boom to 82°.

Axle load tables

Rigged counterweight in t (lbs)

The axle loads specified in the following tables refer to a driving mode with the basic unit and a 40 t hook block (88 200 lbs) reeved on the main boom.

Larger hook blocks must be unreeved.

Position of the MWL

Telescoping of telescopic section I/II/III/IV

Main boom angle in °

Boom position1)

Axle load2) in t (x 1000 lbs) front

rear

60 (132 200)

set down

0/0/0/0

82

rear

17.0 (37.5)

28.0 (61.8)

80 (176 300)

raised (90°)

0/0/0/0

82

rear

24.0 (53.0)

28.0 (61.8)

100, 120, 140, 160

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 80 t (176 300 lbs).

1)

2)

Boom position to the rear =

0° position, boom over rear edge of the chassis

Boom position at the front =

180° position, boom over driver's cab

Axle load to the front:

on the first, second and third axle lines

Axle load to the rear:

on the fourth, fifth, sixth and seventh axle lines

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6 - 31

Operation with the main boom and the MWL 6.5 Driving with rigged truck crane and rigged MWL

6.5.3

Driving the rigged truck crane

Checking the superstructure lock

4 Retracting the outriggers

G

When driving with a rigged crane, the superstructure must be locked to the Operating instructions GMK 7450 – Locking/unlocking the turntable. carrier;

à

• Check if the symbol for the Locked position is shown in green on the Crane control display in the Superstructure lock submenu.

• Retract the outrigger cylinders until the wheels are just above the ground.

Risk of overturning.

Make sure that the truck crane does not overturn while the outrigger cylinders are being retracted.

Retract all the outrigger cylinders as uniformly as possible.

Switching over the suspension locking system

u

• Switch off the suspension locking system. To do this, push in the Suspension locking system rocker switch at the top. The Suspension locking system indicator lamp must extinguish.

All wheels are now lowered to the ground.

• Retract the outrigger cylinders so far that the truck crane is located on a level where there is still enough room to move in both directions.

G G 6 - 32

• Switch the suspension locking system back on again. To do this, push the Suspension locking system rocker switch at the bottom. The Suspension locking system indicator lamp lights up as soon as the suspension system is locked.

• Continue to retract the outrigger cylinders.

Risk of overturning when switching off the suspension locking system.

As long as the truck crane is on wheels, you may not turn off the suspension locking system for any reason. The suspension is no longer under pressure and when the suspension locking system is switched off, the suspension struts would be pressed together, damaged and the truck crane could tip over.

Risk of overturning.

To reduce the risk of the crane overturning do not raise the outrigger pads more than 5 to 10 cm (2 to 4 in) off the ground. Leave the outrigger beams extended.

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MWL Operating instructions GMK 7450

27.09.2004

u

Operation with the main boom and the MWL 6.5 Driving with rigged truck crane and rigged MWL

Driving

S S H

Risk of damage to tyres.

Check the pressure in the tyres before moving the rigged truck crane.

The truck crane may only be moved if the tyre pressures are at the preOperating instructions GMK 7450 – Checking the tyres. Do scribed levels; not reduce the tyre pressure.

à

Risk of damaging the steering linkage.

Steer the truck crane only when the vehicle is moving. The steering linkage can be damaged if the steering is turned while the vehicle is stationary.

Check the wind speed before moving the rigged truck crane. The same maximum permitted wind speeds apply for moving the crane as for working Operating instructions GMK 7450 – Influence of wind on crane with the crane; operation.

à

• Switch the transfer case to off-road gear to move the truck crane; à Operating instructions GMK 7450 – Off-road gear.

]

• Select first gear as the starting gear and also select first gear as the highest possible gear; à Operating instructions GMK 7450 – Operating the automatic transmission – starting and Driving and changing gears.

• Drive as slowly as possible!

• The radius should be as large as possible when turning corners.

• Steer the truck crane only while it is moving and avoid sudden steering movements.

When the surface is uneven the truck crane must be raised with the outrigger cylinders, horizontally aligned and then re-lowered.

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MWL Operating instructions GMK 7450

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6 - 33

Operation with the main boom and the MWL 6.5 Driving with rigged truck crane and rigged MWL

Supporting the truck crane

G If necessary, rig the counterweight sections

Before beginning crane work, support the truck crane with the outrigger Operating instrucspan required for the planned use of the truck crane; tions GMK 7450 – Outriggers.

à

Risk of overturning.

The truck crane must be raised until no wheels touch the ground.

If you have rigged the counterweight sections before moving, you have to now rig these sections again.

With raised MWL

• Rig the relevant counterweight sections with an auxiliary crane.

• Enter the rigging mode for the currently rigged counterweight for operation with main boom and MWL on the SLI display.

With MWL set down

• Enter the rigging mode with 0 t (0 lbs) counterweight for operation with main boom and without MWL on the SLI display.

• Lower the counterweight onto the counterweight platform.

• Unrig the relevant counterweight sections.

• Lock the remaining counterweight on the turntable.

• Enter the rigging mode for the currently rigged counterweight for opera-

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tion with main boom without MWL on the SLI display.

6 - 34

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MWL Operating instructions GMK 7450

7 7

Operation with boom extension and MWL

7.1

Further rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.2 7.2.1 7.2.2 7.2.3 7.3 7.3.1 7.3.2

CHECKLIST: Rigging for operation with boom extension . . . . . . . . . . . . . . . . .

CHECKLIST: Unrigging after operation with the boom extension. . . . . . . . . . .

Installing the deflection sheave with support roller . . . . . . . . . . . . . . . . . . . . . .

Positioning the supporting roller on the foot section . . . . . . . . . . . . . . . . . . . . .

Extra information on positioning the hoist rope with rigged MWL. . . . . . . . . .

3

77777-

3 4 5 6 7

Operation with braced boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

9

CHECKLIST: Bringing the boom system into the operating condition . . . . . . . 7 - 9 CHECKLIST: Bringing the boom system into the rigging mode . . . . . . . . . . . . 7 - 10 Setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 Operation with MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13 Bringing the boom system into the operating condition . . . . . . . . . . . . . . . . . . 7 - 13 Bringing the boom system into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . 7 - 15

7.4

Rigging mode with unbraced boom system and raised MWL . . . . . . . . . . . . . . . 7 - 17

7.5

Driving with rigged crane and rigged boom extension with rigged MWL . . . . . 7 - 19 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20 Rigging modes for moving and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25

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7.5.1 7.5.2 7.5.3

MWL Operating instructions GMK 7450

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL

7

Operation with boom extension and MWL

G H

Risk of accidents if the safety information is ignored.

For operation with the boom extension and MWL, all warnings given in the GMK 7450 Lattice extension operating instructions also apply.

This chapter merely supplements the GMK 7450 lattice extension operating instructions through the addition of information necessary when operating the boom extension together with the MWL.

Operation with an braced boom system is only permissible with the boom extensions 12 m (39 ft), 18 m (59 ft) and 24 m (79 ft). There are only lifting capacity tables and SLI codes for operation with boom extension and MWL for these boom extensions.

In the following sections there is information on the further procedure for operating with the boom extension and the MWL after the MWL has been rigged.

– The section Further rigging work contains information on further rigging work specifically for operation with the boom extension and the MWL, and on preparations for unrigging.

– The section Operation with braced boom system contains all the information required to set the SLI, telescope with rigged MWL as well as for folding in and out and bracing the boom system.

– The section Operation with MWL set down contains all the information required to operate the boom extension when the MWL is rigged but neither raised nor braced.

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

MWL Operating instructions GMK 7450

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7-1

Operation with boom extension and MWL

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7-2

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.1 Further rigging work

7.1

Further rigging work

7.1.1

CHECKLIST: Rigging for operation with boom extension

H

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

Observe the warning and safety instructions given there.

1. The MWL was rigged in accordance with the chapter MWL – Rigging and unrigging; CHECKLIST: Rigging the MWL, p. 5 - 5.

à

2. If necessary, install the deflection sheave with support roller on the foot Installing the deflection sheave with support roller, p. 7 - 5. section;

à

3. If necessary, fold the support roller on the foot section into the position Transport/Rig hoist rope; Positioning the supporting roller on the foot section, p. 7 - 6.

à

4. Rig the boom extension required as described in the GMK 7450 Lattice extension operating instructions. To position the hoist rope; Extra information on positioning the hoist rope with rigged MWL, p. 7 - 7.

à

5. Fold the support roller on the foot section into the Operation position; Positioning the supporting roller on the foot section, p. 7 - 6.

à

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6. Bring the boom system into the operating condition required: – For operation with braced boom system; – For operation with MWL set down;

MWL Operating instructions GMK 7450

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à p. 7 - 9

à p. 7 - 13.

7-3

Operation with boom extension and MWL 7.1 Further rigging work

7.1.2

CHECKLIST: Unrigging after operation with the boom extension

H

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

Observe the warning and safety instructions given there.

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

1100

à p. 7 - 10

à p. 7 - 15.

2. The current rigging mode for operation with the boom extension is entered on the SLI.

3. Bring the hinged support roller on the foot section of the boom extension into the position Transport/Rig hoist rope; Positioning the supporting roller on the foot section, p. 7 - 6.

à

4. Unrig the boom extension as described in the lattice extension operating instructions GMK 7450; lattice extension operating instructions GMK 7450 - Heavy load lattice extension- CHECKLIST: Unrigging the boom extension.

à

à CHECKLIST: MWL – unrigging,

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5. To continue unrigging the MWL; p. 5 - 10.

7-4

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.1 Further rigging work

7.1.3

Installing the deflection sheave with support roller For operation with the MWL, the deflection sheave with hinged support roller (1) must be installed on the foot section of the boom extension (of the luffing jib). Depending on the serial number of the truck crane, this deflection sheave is either already installed or supplied along with the MWL. – If the deflection sheave is installed, the rigging work described in this section is superfluous.

– If the deflection sheave is supplied detached, you must install it before using the boom extension or the luffing jib.

Installing the deflection sheave

Once you have installed the deflection sheave, it can stay installed. This deflection sheave is also intended for operation of the lattice extension without MWL. Installing the deflection sheave

• Sling the deflection sheave (2) to the small safety roller.

• Remove the retaining pins and pull the pins (1) out of the connection points (3).

• Remove the deflection sheave (2).

• Sling the deflection sheave (4) to the hinged support roller.

• Raise the deflection sheave (4) onto the foot section and position it so that the connecting points (3) are aligned.

• Reinsert the pins (1) into the connection points (3).

• Secure the pins (1) using the retaining pins.

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• Remove the lifting gear.

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7-5

Operation with boom extension and MWL 7.1 Further rigging work

7.1.4

Positioning the supporting roller on the foot section For operation with the MWL, the deflection sheave with hinged support roller (1) must be installed on the foot section of the boom extension (of the luffing jib). The support roller has two positions, Transport/Rig hoist rope and Operation.

The position Transport/Rig hoist rope

• Release the retaining pin and remove the pin (2) from the connection points (4).

• Clap the support roller (2) to the side (A).

• Insert the pin (1) through the bore holes (3) and secure it with a retaining pin.

The position Operation

• Release the retaining pin and remove the pin (1) from the bore holes (3).

• Clap the support roller (2) upwards (B).

• Insert the pin (1) through the connection

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points (4) and secure it with a retaining pin.

7-6

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.1 Further rigging work

7.1.5

Extra information on positioning the hoist rope with rigged MWL For operation with MWL and boom extension, you can either use the main hoist rope or the auxiliary hoist rope. However, only one hoist rope can be reeved on the main boom.

G G

Danger of accidents due to overloading!

When operating the boom extension, there must be no hook block reeved on the main boom, even if the boom system is braced.

This hook block or load is not detected by the SLI and the truck crane can become overloaded.

Be careful not to damage the rope protection rolls!

Always secure the hoist rope on the rear deflection sheave of the foot section with the MWL operation support roller.

This prevents the rope protection rolls from becoming overloaded and rupturing.

The hoist ropes required are pulled to the front and are already positioned on the required raising frame deflection sheave.

• Clap the support roller (5) on the foot section to one side, into the Transport/Rig hoist rope p. 7 - 6. position;

à

• Lead the hoist rope from the corresponding deflection sheave (1) on the raising frame over the rear deflection sheave (2) of the foot section.

• Clap the support roller (5) upwards into the Operation position; à p. 7 - 6.

To place the hoist rope on the front deflection sheave (3), and on the deflection sheaves (4) on the angle piece and on the head piece, proceed in the same way as for operation without MWL; GMK 7450 Lattice extension operating instructions – Boom extension – Positioning and reeving the hoist rope.

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à

MWL Operating instructions GMK 7450

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7-7

Operation with boom extension and MWL 7.1 Further rigging work

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7-8

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.2 Operation with braced boom system

7.2

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

For operation with rigged but unraisedMWL; down, p. 7 - 13.

H 7.2.1

à Operation with MWL set

All information in this chapter applies only for the boom extensions of 12 m (39 ft), 18 m (59 ft) and 24 m (79 ft). If other boom extensions are rigged, operation with a braced boom system is not permissible.

CHECKLIST: Bringing the boom system into the operating condition

H 1100

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.

1. Select the actual rigging mode for operation with boom extension and MWL on the SLI, or set the respective SLI code according to the Lifting capacity table; Setting the SLI, p. 7 - 11.

à

2. Telescope the main boom to the telescoping required for operation according to the Lifting capacity table. Telescoping takes place in the same way as for operation with the main boom without boom extension; Telescoping with rigged MWL, p. 6 - 14.

à

3. Fold out both gantry masts. Folding out takes place in the same way as Folding for operation with the main boom without boom extension; the gantry masts out/in, p. 6 - 15.

à

4. Derrick the main boom to the bracing angle required and brace the boom system. Derricking and bracing takes place in the same way as Brace for operation with the main boom without boom extension; the boom system, p. 6 - 17.

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à

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7-9

Operation with boom extension and MWL 7.2 Operation with braced boom system

7.2.2

CHECKLIST: Bringing the boom system into the rigging mode

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.

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

1100

2. The current rigging mode for operation with the boom extension and Setting the SLI, p. 7 - 11.

MWL is entered on the SLI;

à

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

4. To unlock the MWL, derrick the main boom to the bracing angle; Derricking to the bracing angle, p. 6 - 17.

à

à Folding the gantry masts out/in, p. 6 - 15.

Retract the main boom completely; à Telescoping with rigged MWL,

5. Fold in the gantry masts; 6.

p. 6 - 14.

7. Slew the superstructure into the position for unrigging (preferably to the rear) and lower the main boom to the horizontal.

à CHECKLIST: Unrigging after opera-

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8. To continue unrigging the MWL; tion with the boom extension, p. 7 - 4.

7 - 10

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.2 Operation with braced boom system

7.2.3

Setting the SLI On the SLI, a rigging mode for the truck crane with boom extension that is also permissible for operation with the MWL is entered first (to enter the rigOperating instructions GMK 7450 – Part 2 Crane operation – ging mode, Crane operation).

In conclusion, the MWL is entered for this rigging mode.

à

The submenu Enter rigging mode shows the rigging mode entered, e.g.: – Counterweight version 120 t – Boom extension 24 m (79 ft), 3° – Outrigger span 8.76 x 8.90 m (28.7 x 29.2 ft) – ±180° slewing range The SLI code display (3) shows the corresponding SLI code, e.g. 1362.

The Current boom system display (1) shows a truck crane with boom extension.

• Press the button beside the symbol Enter MWL (2) once. The button next to the symbol is only active when the MWL is in the Raised to 90° position.

H

If it is not permissible to operate the MWL with the rigging mode shown, there will be no change on the display.

If operation with the MWL is permissible with the rigging mode shown: – the symbol Enter MWL (2) is highlighted in green – the Current boom system display (1) shows a truck crane with boom extension and MWL – the SLI code display (3) shows the corresponding SLI code for operation with MWL, e.g. 3362.

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• Accept the rigging mode selected (2x Ö ).

s MWL Operating instructions GMK 7450

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7 - 11

Operation with boom extension and MWL 7.2 Operation with braced boom system

The submenu SLI monitoring now shows the selected rigging mode with MWL. The Maximum load display (1) shows the load of the rigging curve for the current rigging mode according to the Lifting capacity table, e.g.

5.0 t (11 000 lbs).

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The SLI will only enable the increased lifting capacity for operation with MWL when the MWL is braced.

7 - 12

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.3 Operation with MWL set down

7.3

Operation with MWL set down This section only describes operation with the main boom and MWL set down. The boom system is not braced and increased lifting capacity will not be enabled.

S 7.3.1

Risk of damage to the hoist rope!

When the MWL is set down, only operation with the main hoist is permitted. If the auxilliary hoist rope is led over the right-hand rope sheave on the raising frame, the hoist rope runs at an impermissible angle and could cause damage, causing the load to fall.

Bringing the boom system into the operating condition This section presumes that the MWL is rigged as described in the checklist Rigging the MWL for operation with MWL set down.

If previously operated with the boom system braced, check that the following conditions are met.

– The guy ropes are removed from the lateral head sheaves and are lying, lightly taut, on the brackets on the gantry masts; Removing the guy rope, p. 5 - 62.

à

– The MWL is set down on the main boom;

à MWL – setting down, p. 5 - 71.

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7 - 13

Operation with boom extension and MWL 7.3 Operation with MWL set down

Setting the SLI

For operation with the MWL set down, you must enter the current rigging mode for operation with the boom extension without MWL on the SLI.

• Enter the current rigging mode.

For operation with MWL set down: – the Current boom system display (1) must shown a truck crane with boom extension and without MWL – the SLI code display (3) must show an SLI code for operation with the main boom, e.g.

1362.

• Accept the rigging mode selected (2x Ö ).

The symbol Input MWL (2) is shown in light grey when the MWL is set down and the button next to the symbol is not active.

The SLI now takes into account the Lifting capacity table corresponding to the SLI code displayed for operation with the boom extension.

When the MWL is set down, the values specified in the Lifting capacity tables are reduced.

The decreased values are shown directly in the Maximum load display (1).

To calculate these values for operation planning, there are corresponding formulas and examples in the Lifting capacity tables in the chapter Notes.

H

The display Maximum load (1) only shows the reduced values when the MWL is connected electrically. Otherwise, the values from the lifting capacity tables will be shown – however, the reduced values still apply for shutdown of the system.

à Malfunctions on the SLI, p. 10 - 7.

27.09.2004

If error messages occur;

7 - 14

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.3 Operation with MWL set down

Telescoping

G Working with the boom extension

7.3.2

Telescoping with MWL set down is done in the same way as for operation with boom extension without MWL. Risk of damage to the lateral head sheaves and the guy ropes.

Make sure that the guy ropes have been removed from the lateral head sheaves before telescoping the main boom with the MWL set down. In this way you prevent damage to the lateral head sheaves or the guy ropes during telescoping.

Operation of the power units when working with the boom extension with MWL set down is the same as for working with the boom extension without GMK 7450 Lattice extension operating instructions – Boom extension.

MWL;

à

Bringing the boom system into the rigging mode Operation of the power units when working with MWL set down is the same GMK 7450 Lattice as for working with the boom extension without MWL; extension operating instructions – Boom extension.

à

This section presumes that – the truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal.

– the actual rigging mode for operation with the boom extension is entered on the SLI.

• Set down the load.

• Fully retract the main boom.

• Slew the superstructure into the position for unrigging (preferably to the rear) and lower the main boom to the horizontal.

à CHECKLIST: Unrigging after operation

27.09.2004

To continue unrigging the MWL; with the boom extension, p. 7 - 4.

MWL Operating instructions GMK 7450

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7 - 15

Operation with boom extension and MWL 7.3 Operation with MWL set down

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7 - 16

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.4 Rigging mode with unbraced boom system and raised MWL

7.4

Rigging mode with unbraced boom system and raised MWL The rigging mode with rigged boom extension, raised MWL and unbraced boom system is not for use when telescoping.

As long as the MWL is unbraced, the SLI only enables the lifting capacity of the empty hook curve. There are no lifting capacity tables for this rigging mode; therefore, it is not permissible to raise loads in this rigging mode.

27.09.2004

G

Risk of overturning in an impermissible operating mode when SLI is overridden.

Operation with the boom extension is not permitted with the MWL raised and the boom system unbraced.

Do not on any account override the SLI in order to raise loads in this mode whose weight exceeds the values of the empty hook curve.

This prevents the truck crane from overturning.

MWL Operating instructions GMK 7450

2 084 909 en

7 - 17

Operation with boom extension and MWL 7.4 Rigging mode with unbraced boom system and raised MWL

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Blank page

7 - 18

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

7.5

Driving with rigged crane and rigged boom extension with rigged MWL This section describes how to move the truck crane with an installed counterweight, rigged boom extension and rigged MWL.

H

Risk of accidents.

You must not 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 brake must be engaged.

Risk of accidents when you cannot see the entire truck crane.

While driving the rigged truck crane, always stay in visual or radio contact with a banksman who additionally observes the parts which you cannot see (e.g. the raised boom in cases where the superstructure is turned to the back).

This will prevent accidents resulting from collisions with persons, other construction equipment, ledges of buildings, cables or other objects.

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G G G

When driving with a rigged boom extension, always switch on the separate steering and do not steer if stationary.

MWL Operating instructions GMK 7450

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7 - 19

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

7.5.1

Driving route The route must be along 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 area of the tyres must be increased using packing made of a stable material (e.g. wooden planks).

S 7.5.2

Risk of damage to tyres.

Check the pressure in the tyres before moving the rigged truck crane.

The truck crane may be moved only if tyre pressures are at the prescribed GMK 7450 Operating instructions – Part 1 Driving – Technical data – levels Tyres.

On no account should you reduce the tyre pressure!

à

Rigging modes for moving and axle loads The truck crane may only be moved under certain circumstances. A part of the counterweight must be unrigged depending on the counterweight and the main boom and lattice extension must be moved to a specific position.

The tables on the following pages provide an overview of the possible settings.

S Bringing the truck crane into the rigging mode

Risk of damage to the axle lines!

Always move the truck crane to the prescribed rigging mode before you drive the rigged truck crane. Positions that deviate from the rigging mode cause impermissible loads on the axle lines.

One of the following tables shows the required rigging mode for the procedure for the currently rigged boom extension. The rigging mode is defined by: the position of the MWL the angle position of the boom extension the counterweight version the position of the superstructure the telescoping the main boom angle

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– – – – – –

7 - 20

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

• Set down the load; with the exception of the hook block, which is given in the following table, no load may be lifted.

• If applicable, set down the MWL as well; à Setting down the MWL, p. 5 - 57.

• If necessary, set the required angle position of the boom extension;

à Lattice extension operating instructions GMK 7450 – boom extension.

• On the SLI display, enter the current counterweight combination or the counterweight combination that is to be unrigged (e. g. 80 t) (e.g. 176 300 lbs).

• On the SLI display, enter the current rigging mode of the lattice extension: – the length and angle position of the rigged boom extension (e. g. 24 m (79 ft) and 3°) – MWL operation when MWL is raised.

• If necessary, use an auxiliary crane for unrigging in order to obtain the required counterweight combination – procedure for unrigging; Operating instructions Part 2 – Crane operation, chapter Rigging work section Removing and putting down counterweight sections while auxiliary hoist is mounted.

à

• Slew the superstructure into the position required (0° to the rear or 180° to the front).

!

• Lock the superstructure. The Turntable locking status display must show the symbol for the Locked setting in green.

• Derrick the main boom to the required angle for telescopic extension.

You can find the required main boom angle in the Lifting capacity tables, in chapter Rigging table boom extension.

• Telescope the main boom to the required telescoping and lock the telescopic sections.

• Derrick the main boom to the position required.

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MWL Operating instructions GMK 7450

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7 - 21

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

All of the axle loads in the following table refer to a driving mode with the basic unit and on the boom extension 40 t hook block (88 200 lbs) reeved on the boom extension; larger hook blocks must be unreeved.

Inclination Main boom in °

Inclination Lattice extension in °

Main boom position1)

front

88 - 0 - 0 - 0

15

3

front

21.5 (47.4)

21.0 (46.3)

0-0-0-0

82

3

rear

13.0 (28.7)

27.5 (60.6)

44 - 0 - 0 - 0

15

3

front

17.0 (37.5)

24.5 (54.0)

0-0-0-0

82

3

rear

15.5 (34.2)

26.0 (57.3)

88 - 44 - 0 - 0

15

3

front

21.0 (46.3)

26.5 (58.4)

88 - 44 - 0 - 0

15

3

front

22.5 (49.6)

25.5 (56.2)

0-0-0-0

82

3

rear

19.5 (43.0)

28.0 (61.7)

set down 40 (88 100) raised (90°)

set down 60 (132 200)

over 60 (132 200)

raised (90°)

Axle load2) in t (x 1000 lbs)

Telescoping of telescopic section I/II/III/IV

Position of the MWL

Rigged counterweight in t (lbs)

12 m (39 ft)-boom extension

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 60 t (132 200 lbs).

1)

0° position, boom over rear edge of the chassis

Boom position at the front =

180° position, boom over driver's cab

Axle load to the front:

on the first, second and third axle lines

Axle load to the rear:

on the fourth, fifth, sixth and seventh axle lines

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2)

Boom position to the rear =

7 - 22

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

All of the axle loads in the following table refer to a driving mode with the basic unit and on the boom extension 40 t hook block (88 200 lbs) reeved on the boom extension; larger hook blocks must be unreeved.

Telescoping of telescopic section I/II/III/IV

Inclination Main boom in °

Inclination Lattice extension in °

Main boom position1)

44 - 0 - 0 - 0

15

3

front

17.5 (38.6)

24.5 (54.0)

0-0-0-0

82

3

rear

13.0 (28.7)

28.0 (61.7)

44 - 0 - 0 - 0

15

3

front

19.0 (41.9)

23.5 (51.8)

0-0-0-0

82

3

rear

15.0 (33.1)

26.0 (57.3)

88 - 44 - 0 - 0

15

3

front

23.0 (50.7)

25.5 (56.2)

88 - 0 - 0 - 0

15

3

front

20.0 (44.1)

27.5 (60.6)

0-0-0-0

82

3

rear

19.5 (43.0)

28.0 (61.7)

set down 40 (88 100) raised (90°)

set down 60 (132 200)

over 60 (132 200)

raised (90°)

Axle load2) in t (x 1 000 lbs) front

Position of the MWL

Rigged counterweight in t (lbs)

18 m (59 ft)-boom extension

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 60 t (132 200 lbs).

1)

2)

Boom position to the rear =

0° position, boom over rear edge of the chassis

Boom position at the front =

180° position, boom over driver's cab

Axle load to the front:

on the first, second and third axle lines

Axle load to the rear:

on the fourth, fifth, sixth and seventh axle lines

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MWL Operating instructions GMK 7450

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7 - 23

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

All of the axle loads in the following table refer to a driving mode with the basic unit and on the boom extension 40 t hook block (88 200 lbs) reeved on the boom extension; larger hook blocks must be unreeved.

Telescoping of telescopic section I/II/III/IV

Inclination Main boom in °

Inclination Lattice extension in °

Main boom position1)

44 - 0 - 0 - 0

15

3

front

19.0 (41.9)

23.5 (51.8)

0-0-0-0

82

3

rear

13.0 (28.7)

28.0 (61.7)

44 - 0 - 0 - 0

15

3

front

20.5 (45.2)

22.5 (49.6)

0-0-0-0

82

3

rear

15.5 (33.1)

26.5 (58.4)

set down

88 - 0 - 0 - 0

15

3

front

20.5 (45.2)

27.5 (60.6)

raised (90°)

88 - 0 - 0 - 0

15

3

front

22.0 (48.5)

26.0 (57.3)

set down 40 (88 100) raised (90°)

60 (132 200) over 60 (132 200)

Axle load2) in t (x 1 000 lbs) front

Position of the MWL

Rigged counterweight in t (lbs)

24 m (79 ft)-boom extension

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 60 t (132 200 lbs).

1) Boom position to the rear = Boom position at the front = 2) Axle load to the front:

180° position, boom over driver's cab on the first, second and third axle lines on the fourth, fifth, sixth and seventh axle lines

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Axle load to the rear:

0° position, boom over rear edge of the chassis

7 - 24

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

7.5.3

Driving the rigged crane

Checking the superstructure lock

4 Retracting the outriggers

G

When driving with a rigged crane, the superstructure must be locked to the Operating instructions GMK 7450 – Locking/unlocking the turntable. carrier;

à

• Check if the symbol for the Locked position is shown in green on the Crane control display in the Superstructure lock submenu.

• Retract the outrigger cylinders until the wheels are just above the ground.

Risk of overturning!

Make sure that the truck crane does not overturn while the outrigger cylinders are being retracted.

Retract all the outrigger cylinders as uniformly as possible.

Switching over the suspension locking system

u

• Switch off the suspension locking system. To do this, push in the Suspension locking system rocker switch at the top. The Suspension locking system indicator lamp must extinguish.

All wheels are now lowered to the ground.

• Retract the outrigger cylinders so far that the truck crane is located on a level where there is still enough room to move in both directions.

27.09.2004

u

G

• Switch the suspension locking system back on again. To do this, push the Suspension locking system rocker switch at the bottom. The Suspension locking system indicator lamp lights up as soon as the suspension system is locked.

• Continue to retract the outrigger cylinders.

Risk of overturning when switching off the suspension locking system.

As long as the truck crane is on wheels, you may not turn off the suspension locking system for any reason. The suspension is no longer under pressure and when the suspension locking system is switched off, the suspension struts would be pressed together, damaged and the truck crane could tip over.

s MWL Operating instructions GMK 7450

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7 - 25

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

G

Risk of overturning!

To reduce the risk of the crane overturning do not raise the outrigger pads more than 5 to 10 cm (2 to 4 in) off the ground. Leave the outrigger beams extended.

Driving

S S H

Risk of damage to tyres!

Check the pressure in the tyres before moving the rigged truck crane.

The truck crane may only be moved if the tyre pressures are at the prescribed levels; à Operating instructions GMK 7450 – Checking the tyres. Do not reduce the tyre pressure.

Risk of damaging the steering linkage!

Steer the truck crane only when the vehicle is moving. The steering linkage can be damaged if the steering is turned while the vehicle is stationary.

Check the wind speed before moving the rigged truck crane. The same maximum permitted wind speeds apply for moving the truck crane as for workOperating instructions GMK 7450 – Influence of wind on ing with the crane; crane operation.

à

• Switch the transfer case to off-road gear to move the truck crane; à Operating instructions GMK 7450 – Off-road gear.

]

• Select first gear as the starting gear and also select first gear as the highest possible gear; à Operating instructions GMK 7450 – Operating the automatic transmission – starting and Driving and changing gears.

• Drive as slowly as possible!

• The radius should be as large as possible when turning corners.

• Steer the truck crane only while it is moving and avoid sudden steering movements.

When the surface is uneven the truck crane must be raised with the outrigRetracting the ger cylinders, horizontally aligned and then re-lowered; outriggers, p. 7 - 25 and Switching over the suspension locking system, p. 7 - 25.

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à

7 - 26

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MWL Operating instructions GMK 7450

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

Supporting the truck crane

G If necessary, rig the counterweight sections

Before beginning crane work, support the truck crane with the outrigger Operating instrucspan required for the planned use of the truck crane; tions GMK 7450 – Outriggers.

à

Risk of overturning!

The truck crane must be raised until no wheels touch the ground.

If you have unrigged the counterweight sections before moving, you have to now rig these sections again.

• On the SLI display, enter the counterweight version that is to be rigged (e. g. 80 t (176 300 lbs)).

• Rig the relevant counterweight parts with an auxiliary crane. Procedure

à

27.09.2004

Operating instructions Part 2 – crane operation, chapter Rigfor rigging; ging work – section Removing and putting down counterweight sections while auxiliary hoist is mounted.

MWL Operating instructions GMK 7450

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7 - 27

Operation with boom extension and MWL 7.5 Driving with rigged crane and rigged boom extension with rigged MWL

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Blank page

7 - 28

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MWL Operating instructions GMK 7450

8 8

Operation with the luffing jib and the MWL

8.1

Additional display in the submenu Operation – MWL . . . . . . . . . . . . . . . . . . . . . . 8 -

2

8.2

Further rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

3

8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6 8.4 8.4.1 8.4.2

CHECKLIST: Rigging for operation with luffing jib . . . . . . . . . . . . . . . . . . . . . . .

CHECKLIST: Unrigging after operation with the luffing jib . . . . . . . . . . . . . . . .

Installing the deflection sheave with support roller . . . . . . . . . . . . . . . . . . . . . .

Positioning the supporting roller on the foot section . . . . . . . . . . . . . . . . . . . . .

Extra information on positioning the hoist rope with rigged MWL. . . . . . . . . .

88888-

3 5 6 7 8

Operation with braced boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

9

CHECKLIST: Bringing the boom system into operating condition . . . . . . . . . .

CHECKLIST: Bringing the boom system into rigging mode. . . . . . . . . . . . . . . .

Setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking main boom with rigged luffing jib and rigged MWL . . . . . . . . . . . .

Telescoping main boom with rigged luffing jib and rigged MWL. . . . . . . . . . .

Bracing boom system with rigged luffing jib . . . . . . . . . . . . . . . . . . . . . . . . . . .

888888-

9 13 17 19 20 22

Operation with MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23 Bringing the boom system into the operating condition . . . . . . . . . . . . . . . . . . 8 - 23 Bringing the boom system into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . 8 - 25

8.5

Rigging mode with unbraced boom system and raised MWL . . . . . . . . . . . . . . . 8 - 27

8.6

Driving with rigged crane, rigged luffing jib and rigged MWL . . . . . . . . . . . . . . . 8 - 29 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29 Rigging modes for moving and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 39

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8.6.1 8.6.2 8.6.3

MWL Operating instructions GMK 7450

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL

8

Operation with the luffing jib and the MWL

G

Risk of accidents if the safety information is ignored.

For operation of the luffing jib with MWL, all warnings given in the Lattice extension operating instructions GMK 7450 also apply.

This chapter merely supplements the Lattice extension operating instructions GMK 7450 through the addition of information necessary when operating the luffing jib together with the MWL.

In the following sections there is information on the further procedure for operating with the luffing jib and the MWL after the MWL has been rigged.

– The section Further rigging work contains information on further rigging work specifically for operation with the luffing jib and MWL and on preparations for unrigging.

– The section Operation with braced boom system contains all the information required to set the SLI as well as information about putting the luffing jib into operating condition and rigging mode.

– The section Operation with MWL set down contains all the information required to operate using the luffing jib when the MWL is rigged but neither raised nor braced.

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– The section Driving with rigged crane, rigged luffing jib and rigged MWL contains information about boom positions, special rigging codes and the axle loads created when driving the truck crane with rigged MWL.

MWL Operating instructions GMK 7450

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8-1

Operation with the luffing jib and the MWL 8.1 Additional display in the submenu Operation – MWL

8.1

Additional display in the submenu Operation – MWL When the luffing jib is switched on electrically, an additional display will appear in the Operation – MWL submenu.

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

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

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2 A red symbol (≠ 7°) will appear if the luffing jib is not positioned at the bracing angle.

8-2

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.2 Further rigging work

8.2

Further rigging work

8.2.1

CHECKLIST: Rigging for operation with luffing jib

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.

1. The MWL was rigged in accordance with the chapter MWL – Rigging and unrigging; CHECKLIST: Rigging the MWL, p. 5 - 5.

à

2. The counterweight required for the planned job has been rigged and Operating instructions GMK 7450. the auxiliary hoist has been rigged; 3.

à The rope grab has been removed; à p. 5 - 20.

4. If necessary, install the deflection sheave with support roller on the foot Installing the deflection sheave with support roller, p. 8 - 6. section;

à

5. If necessary, fold the support roller on the foot section into the position Transport/Rig hoist rope; Positioning the supporting roller on the foot section, p. 8 - 7.

27.09.2004

à

6. If the MWL has been set down, carry out the following rigging work as described in the Lattice extension operating instructions GMK 7450: – Lock foot section to main boom head – Place the luffing control arm onto the rigging supports – Reeve the upper hook block and fasten to luffing control arm – Replace the intermediate section of foot section if necessary – Unlock hinge lock in the foot section – Install all parts required for luffing jib – Establish electric connections – Set the angle position if necessary – Transfer lifting limit switch, anemometer and, if necessary, air traffic control lights to the head of the luffing jib.

s

MWL Operating instructions GMK 7450

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8-3

Operation with the luffing jib and the MWL 8.2 Further rigging work

7. Lay hoist rope, making sure to follow the instructions contained in the section Extra information on positioning the hoist rope with rigged MWL; p. 8 - 8.

à

8. Fold the support roller on the foot section into the Operation position; Positioning the supporting roller on the foot section, p. 8 - 7.

à

9. Bring the boom system into the operating condition required: – For operation with braced boom system;

à p. 8 - 23.

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– For operation with MWL set down;

à p. 8 - 9

8-4

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.2 Further rigging work

8.2.2

CHECKLIST: Unrigging after operation with the luffing jib

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.

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

1100

à p. 8 - 13

à p. 8 - 25.

2. The current rigging mode for operation with the luffing jib is entered on the SLI; Setting the SLI, p. 8 - 17.

à

3. Bring the hinged support roller on the foot section of the luffing jib into the position Transport/Rig hoist rope; Positioning the supporting roller on the foot section, p. 8 - 7.

à

4. Carry out the following rigging work as described in the Lattice extension operating instructions GMK 7450: – Set angle to 0° if necessary – Disconnect electric connections – Remove all boom sections up to the foot section – Block the joint in the foot section – Detach the upper hook block from the luffing control arm and attach to the catcher on the auxiliary hoist – Remove lifting limit switch, anemometer and, if necessary, air traffic control lights from the head of the luffing jib.

– Remove foot section from main boom head

à CHECKLIST: MWL – unrigging,

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5. To continue unrigging the MWL; p. 5 - 10.

MWL Operating instructions GMK 7450

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8-5

Operation with the luffing jib and the MWL 8.2 Further rigging work

8.2.3

Installing the deflection sheave with support roller For operation with the MWL, the deflection sheave with hinged support roller (1) must be installed on the foot section of the luffing jib (of the boom extension). Depending on the serial number of the truck crane, this deflection sheave is either already installed or supplied along with the MWL. – If the deflection sheave is installed, the rigging work described in this section is superfluous.

– If the deflection sheave is supplied detached, you must install it before using the boom extension or the luffing jib.

Installing the deflection sheave

Once you have installed the deflection sheave, it can stay installed. This deflection sheave is also intended for operation of the lattice extension without MWL. Installing the deflection sheave

• Sling the deflection sheave (2) to the small safety roller.

• Remove the retaining pins and pull the pins (1) out of the connection points (3).

• Remove the deflection sheave (2).

• Sling the deflection sheave (4) to the hinged support roller.

• Raise the deflection sheave (4) onto the foot section and position it so that the connecting points (3) are aligned.

• Reinsert the pins (1) into the connection points (3).

• Secure the pins (1) using the retaining pins.

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• Remove the lifting gear.

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Operation with the luffing jib and the MWL 8.2 Further rigging work

8.2.4

Positioning the supporting roller on the foot section For operation with the MWL, the deflection sheave with hinged support roller (1) must be installed on the foot section of the luffing jib (of the boom extension). The support roller has two positions, Transport/Rig hoist rope and Operation.

Transport/Rig hoist rope position

• Release the retaining pin and remove the pin (2) from the connection points (4).

• Clap the support roller (2) to the side (A).

• Insert the pin (1) through the bore holes (3) and secure it with a retaining pin.

Operation position

• Release the retaining pin and remove the pin (1) from the bore holes (3).

• Clap the support roller (2) upwards (B).

• Insert the pin (1) through the connection

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points (4) and secure it with a retaining pin.

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8-7

Operation with the luffing jib and the MWL 8.2 Further rigging work

8.2.5

Extra information on positioning the hoist rope with rigged MWL The main hoist rope has been pulled forward, is resting on the raising frame on the right-hand deflection sheave (1) and is secured using the rope holding roller (2).

G

Be careful not to damage the rope holding rollers!

Always secure the hoist rope on the rear deflection sheave of the foot section with the MWL operation support roller.

This prevents the rope holding rollers from becoming overloaded and rupturing.

• Clap the support roller (5) on the foot section to one side, into the Transport/Rig hoist rope p. 8 - 7. position;

à

• Guide the main hoist rope from the righthand deflection sheave (1) on the raising frame over the rear deflection sheave (2) of the foot section.

• Move the support roller (5) upwards into the Operation position; à p. 8 - 7.

To place the hoist rope on the front deflection sheave (3), and on the deflection sheaves (4) on the angle piece and on the head piece, proceed in the same way as for operation without MWL; Lattice extension operating instructions GMK 7450 – Luffing jib – Positioning and reeving the hoist rope.

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à

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

8.3

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

For operation with rigged but unraised MWL; down, p. 8 - 23.

8.3.1

à Operation with MWL set

CHECKLIST: Bringing the boom system into operating condition

H 1100

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.

1. Select the actual rigging mode for operation with luffing jib and the MWL for a main boom angle of 81° on the SLI, or set the corresponding Setting the SLI, SLI code according to the Lifting capacity table; p. 8 - 17.

à

2. Open luffing jib submenu (0); GMK 7450.

à Lattice extension operating instructions

3. Raise the luffing control arm using the auxiliary hoist until the Luffing control arm raised symbol (!) is highlighted in yellow. When the background changes to yellow, the auxiliary hoist is switched off.

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4. From the Luffing jib submenu, first switch to the Operation-MWL submenu (1). From there, switch to the Rigging-MWL (U) submenu.

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8-9

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

5. Raise MWL until the symbol for the end position Raised to 90° (X) is MWL – raising, p. 5 - 70. shown in green;

à

6. Lay the guy ropes on both sides, pull slightly taut and release the lateral head sheave; Positioning/removing the guy ropes, p. 5 - 60, Securing/releasing the lateral head sheaves, p. 5 - 66.

à à

7. From the Rigging-MWL submenu, first switch to the Operation-MWL submenu (1). From there, switch to the Luffing jib submenu (0).

8. Raise main boom until the upper area of the indicator lamp Steepest/flattest position ($) changes from red to grey (SLI display, luffing jib angle approx. 10°).

The movement Lift auxiliary hoist is now enabled.

9. Raise the luffing jib using the auxiliary hoist until the height required for reeving the main hoist rope has been reached.

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10. Reeve the main hoist rope on the hook block and place lifting limit switch weight around the hoist rope.

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

11. If the lifting limit switch was blocked before beginning the rigging work, GMK 7450 Operating you should now unblock the lifting limit switch; instructions – blocking/releasing the block on the lifting limit switch.

à

II

6

12. Enter current reeving on the SLI (e.g. 6-fall); GMK 7450 – Crane operation.

à Operating instructions

à Derricking main boom with rigged luffing jib

13. Raise main boom to 81°; and rigged MWL, p. 8 - 19.

14. Derrick luffing jib into telescoping range (1); ing instructions GMK 7450.

à Lattice extension operat-

15. Telescope the main boom out to a position permissible according to the Lifting capacity table and lock the telescopic sections; Telescoping main boom with rigged luffing jib and rigged MWL, p. 8 - 20.

à

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16. From the Luffing jib submenu, switch to the Operation-MWL submenu (1).

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8 - 11

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

P

Q

17. Fold out both gantry masts;

à Folding the gantry masts out/in, p. 6 - 15.

18. Derrick the luffing jib to the bracing angle required and brace the boom system; Bracing boom system with rigged luffing jib, p. 8 - 22.

à

If operation at a main boom angle of 60° or 70° is required:

1100

19. On the SLI, enter the rigging mode with luffing jib and MWL for the reSetting the SLI, p. 8 - 17. quired main boom angle (60° or 70°);

à

à Lattice extension op-

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20. Lower the main boom into the required position; erating instructions GMK 7450.

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

8.3.2

CHECKLIST: Bringing the boom system into rigging mode

H

The information provided in this section assumes that you are already familiar with the rigging procedure for the luffing jib without MWL. For this reason, procedures such as setting down the luffing jib are only briefly described in checklists. If you need more detailed information covering stepby-step operation of the luffing jib, refer to the supplied Lattice extension operating instructions GMK 7450.

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

1100

2. The current rigging mode for operation with the luffing jib and MWL is entered on the SLI; Setting the SLI, p. 8 - 17.

à

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

4. From the Luffing jib submenu, switch to the Operation-MWL submenu (1).

à Derricking main boom with rigged luffing jib

5. Raise main boom to 81°; and rigged MWL, p. 8 - 19.

G N O

6. To relieve the boom system, unlock the winches; p. 6 - 20.

7. Fold in both gantry masts;

à Unlock winches,

à Folding the gantry masts out/in, p. 6 - 15.

8. Derrick the luffing jib into telescoping range (1); Lattice extension operating instructions GMK 7450.

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à

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Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

9. Retract the main boom completely; luffing jib and rigged MWL, p. 8 - 20.

à Telescoping main boom with rigged

10. From the Operation-MWL submenu, switch to the Luffing jib submenu (0).

11. Lower the main boom until the head section of the luffing jib is just above the ground, while at the same time lowering the luffing jib so that the steepest position is not reached.

S S

Risk of damage to the hoist rope!

Make sure that the hoist rope is not damaged. During the following procedure, set down the hook block as soon as the boomsystem is in an appropriate position, and unreeve the main hoist rope.

Be careful not to damage the fall-back guard strut!

During the following procedure, ensure that the head section does not touch the ground before the luffing control arm has reached the steepest position. When the luffing control arm is inclined forwards, the backtop can touch the foot section and be damaged in the worst case scenario (luffing jib has been set down flat on the ground).

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12. Without touching the ground, move the head section towards the front (combination of lowering the main boom and raising the luffing jib) until the luffing jib is just before the Too steep shutdown area (1) in the Current position display (SLI display, luffing jib angle approx. 10°).

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

13. By lowering the main boom, set the luffing jib onto the ground using the rollers on its head. Continue to lower the main boom until the upper area of the indicator lamp Steepest/flattest position ($) is shown in red (lowering function will be switched off).

14. Lower the luffing control arm until the background of the Luffing control arm raised (!) symbol is shown in grey.

G

Risk of accidents if the main boom is lowered too far!

In the next step, only lower the main boom far enough to allow the locking pin positions for the hinge lock to align. This position can be exceeded when lowering the boom to horizontal, especially with long luffing jibs. The inclinable part of the foot section is pressed against the fixed part; this causes tension. This tension is released when the pins are driven out, and the unexpected slippage of the luffing jib which then occurs can injure you or others.

15. Lower the main boom until the locking points for the hinge lock in the foot section are aligned.

16. From the Luffing jib submenu, first switch to the Operation-MWL submenu (1). From there, switch to the Rigging-MWL (U) submenu.

17. Pull the guy rope slightly taut on both sides and secure the lateral head sheave; Securing/releasing the lateral head sheaves, p. 5 - 66.

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à

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8 - 15

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

18.Loosen the guy rope from the lateral head sheave on both sides, and pull Positioning/removing the guy it up into the bracket on the gantry mast; ropes, p. 5 - 60.

à

F

19. Lock both winches;

à Lock winches, p. 6 - 19.

20. Setting down MWL ;

à MWL – setting down, p. 5 - 71.

21. Set the luffing control arm onto the rigging supports (lower auxiliary hoist).

à CHECKLIST: Unrigging after opera-

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22. To continue unrigging the MWL; tion with the luffing jib, p. 8 - 5.

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

8.3.3

Setting the SLI On the SLI, a rigging mode for the truck crane with luffing jib that is also permissible for operation with the MWL is entered first (to enter the rigging Operating instructions GMK 7450 – Part 2 Crane operation – Crane opmode, eration). Afterwards, the MWL is entered for this rigging mode.

à

The Enter rigging mode submenu shows the rigging mode entered, e.g.: – Counterweight combination 120 t – Luffing jib 37 m (121 ft) no angle position – Main boom angle 81° – Outrigger span 8.76 x 8.90 m (28.7 x 29.2 ft) – Slewing range ±180° The SLI code display (3) shows the corresponding SLI code, e.g. 2362.

The Current boom system display (1) shows a truck crane with luffing jib.

• Press the button beside the symbol Enter MWL (2) once. The button next to the symbol is only active when the MWL is in the Raised to 90° position:

H

If it is not permissible to operate the MWL with the rigging mode shown, there will be no change on the display.

If operation with the MWL is permissible with the rigging mode shown: – The symbol Enter MWL (2) is highlighted in green – the Current boom system display (1) shows a truck crane with luffing jib and MWL – The SLI code display (3) shows the corresponding SLI code for operation with MWL, e.g. 4362.

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• Accept the rigging mode selected (2x Ö ).

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8 - 17

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

The submenu SLI monitoring now shows the selected rigging mode with MWL. The Maximum load display (1) shows the load of the rigging curve for the current rigging mode according to the Lifting capacity table, e.g.

5.0 t (11 000 lbs).

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The SLI will only enable the increased lifting capacity for operation with MWL when the MWL is braced.

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

8.3.4

Derricking main boom with rigged luffing jib and rigged MWL The procedure for derricking the main boom with rigged luffing jib and Luffing jib opMWL is the same as with a rigged luffing jib without MWL; erating instructions GMK 7450.

à

Nevertheless, the requirements for derricking with rigged MWL must be satisfied before enabling the derricking procedure.

• Check that the following conditions are met: In the Operation-MWL submenu The MWL 90°/5° display (1) will show the following: – Either the symbol for the position MWL Raised to 90° in green (X) – Or the symbol for the position MWL Placed under 5° in green (q).

In the Luffing jib submenu: – The indicator lamp in the Rigging operating mode symbol (3) is shown in green.

– The Current position display shows the rigging area (1) in green.

– The Derricking gear display (4) is shown in green.

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– Both sides of the Steepest/flattest position display (2) are shown in grey.

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8 - 19

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

8.3.5

Telescoping main boom with rigged luffing jib and rigged MWL The procedure for telescoping with rigged luffing jib and MWL is the same Luffing jib operating instructions as with a rigged luffing jib without MWL; GMK 7450.

à

Nevertheless, the requirements for telescoping with rigged MWL must be satisfied before enabling the telescoping procedure. Check that the following conditions are met: – There is no load raised other than the hook block.

– The main boom is positioned at 81°.

On the SLI display – Enter rigging mode submenu: – On the Current boom system display (1), the main boom angle of 81° has been selected.

– The SLI code display shows an SLI code for operation with luffing jib and MWL at a main boom angle of 81° (e.g. 4362).

In the Operation-MWL submenu – Both winches are unlocked. The symbols (1) for the end position Unlocked are shown in red.

– Both gantry masts are folded in. The symbols (2) for the end position Folded in are shown in green.

In the Luffing jib submenu: – The Main boom angle display (3) is shown in grey.

– The luffing jib is in telescoping range (1).

– The indicator lamp in the Telescoping operating mode symbol (2) is shown in green.

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– The Telescoping mechanism display (4) is shown in green.

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

H

After all requirements have been met, the telescoping procedure will be enabled. It is a good idea to use the teleautomation after opening the Luffing jib submenu, since the shutdown ranges are also displayed in this menu.

You can also start the teleautomation from the Operation-MWL submenu or from the Telescoping submenu.

Further information on telescoping and automatic function for subsequent Luffing jib operating instructions GMK 7450 – movement of the luffing jib; Luffing jib – Telescoping with luffing jib.

à

If the luffing jibs are rigged at 67 m (220 ft) or more and if a main boom length of 28.60 m (93.8 ft) is reached during telescoping, it may not be possible to telescope the main boom any farther, even though the luffing jib is located within the telescoping range (1).

When telescoping with semi-automatic, you have to raise the luffing jib to an angle of at least 8°. After this has been done, the telescoping procedure will be enabled.

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H

When teleautomation is switched on, the luffing jib is raised automatically to the required angle. The telescoping function is not interrupted.

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8 - 21

Operation with the luffing jib and the MWL 8.3 Operation with braced boom system

8.3.6

Bracing boom system with rigged luffing jib Before the bracing procedure can be enabled, all requirements valid for p. 6 - 18). bracing with rigged luffing jib without MWL must be met (

à

In addition, the following requirements must be met: – The main boom must be raised to an angle of 81°.

– A main boom angle of 81° must be selected on the Current boom system display (1) and an SLI code for operation with a luffing jib and MWL at a main boom angle of 81° must appear on the SLI code display (2) (e.g. 4362).

• Derrick the luffing jib to 7°.

In the Luffing jib submenu symbol (3), the entry =7° must be shown in green.

After all requirements have been met, the following will occur: – The symbol on the Bracing angle display (1) will be shown in green.

– The Boom system bracing symbol (2) will be shown in black, and the button next to the symbol will be active.

à Bracing,

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To brace the boom system; p. 6 - 18.

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.4 Operation with MWL set down

8.4

Operation with MWL set down This section only describes operation with the luffing jib with MWL set down. The boom system is not braced and increased lifting capacity will not be enabled.

8.4.1

Bringing the boom system into the operating condition This section presumes that the MWL is rigged as described in the checklist Rigging the MWL for operation with MWL set down.

If previously operated with the boom system braced, check that the following conditions are met.

– The guy ropes are removed from the lateral head sheaves and are lying, lightly taut, on the brackets on the gantry masts; Removing the guy rope, p. 5 - 62.

à

– The MWL is set down on the main boom;

à MWL – setting down, p. 5 - 71.

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Operation with the luffing jib and the MWL 8.4 Operation with MWL set down

Setting the SLI

For operation with the MWL set down, you must enter the current rigging mode for operation with the luffing jib without MWL on the SLI.

• Enter the current rigging mode.

For operation with MWL set down: – the Current boom system display (1) must show a truck crane with luffing jib and without MWL – the SLI code display (3) must show an SLI code for operation with the main boom, e.g.

2363.

• Accept the rigging mode selected (2x Ö ).

The symbol Input MWL (2) is shown in light grey when the MWL is set down and the button next to the symbol is not active.

The SLI now takes into account the Lifting capacity table corresponding to the SLI code displayed for operation with the luffing jib.

When the MWL is set down, the values specified in the Lifting capacity tables are reduced.

The decreased values are shown directly in the Maximum load display (1).

To calculate these values for operation planning, there are corresponding formulas and examples in the Lifting capacity tables in the chapter Notes.

H

The display Maximum load (1) only shows the reduced values when the MWL is connected electrically. Otherwise, the values from the lifting capacity tables will be shown – however, the reduced values still apply for shutdown of the system.

à Malfunctions on the SLI, p. 10 - 7.

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If error messages occur;

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.4 Operation with MWL set down

Telescoping

G Operation with the luffing jib

8.4.2

Telescoping with MWL set down is done in the same way as for operation Lattice extension operating instructions with luffing jib without MWL; GMK 7450 – Luffing jib.

à

Risk of damage to the lateral head sheaves and guy ropes.

Make sure that the guy ropes have been removed from the lateral head sheaves before telescoping the main boom with the MWL set down. In this way you prevent damage to the lateral head sheaves or the guy ropes during telescoping.

Operation of the power units when working with the boom extension with MWL set down is the same as for working with the boom extension without GMK 7450 lattice extension operating instructions – Boom extension.

MWL;

à

Bringing the boom system into the rigging mode Operation of the power units with MWL set down is the same as working Lattice extension operating instructions with the luffing jib without MWL; GMK 7450 – Luffing jib.

à

This section assumes the following: – the truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal – the actual rigging mode for operation with the luffing jib is entered on the SLI

• Set down the load.

• Fully retract the main boom.

• Slew the superstructure into the position for unrigging (preferably to the rear) and lower the main boom to the horizontal.

à CHECKLIST: Unrigging after operation

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To continue unrigging the MWL; with the luffing jib, p. 8 - 5.

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8 - 25

Operation with the luffing jib and the MWL 8.4 Operation with MWL set down

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.5 Rigging mode with unbraced boom system and raised MWL

8.5

Rigging mode with unbraced boom system and raised MWL The rigging mode with rigged luffing jib, raised MWL and unbraced boom system is not for use with telescoping.

As long as the MWL is unbraced, the SLI only enables the lifting capacity of the empty hook curve. There are no lifting capacity tables for this rigging mode; therefore, it is not permissible to raise loads in this rigging mode.

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G

Risk of overturning in an impermissible operating mode when SLI is overridden.

Operation with the luffing jib is not permitted with the MWL raised and the boom system unbraced.

Do not on any account override the SLI in order to raise loads in this mode whose weight exceeds the values of the empty hook curve.

This prevents the truck crane from overturning.

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8 - 27

Operation with the luffing jib and the MWL 8.5 Rigging mode with unbraced boom system and raised MWL

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

8.6

Driving with rigged crane, rigged luffing jib and rigged MWL This section describes moving the truck crane with an installed counterweight, rigged luffing jib and rigged MWL.

H

G G G 8.6.1

S

When driving with a rigged luffing jib, always switch on the separate steering and do not steer if stationary.

Risk of accidents You must not 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 holding brake must be engaged.

Risk of accidents when you cannot see the entire truck crane While driving the rigged truck crane, always stay in visual or radio contact with a banksman who additionally observes the parts which you cannot see (e.g. the raised boom in cases where the superstructure is turned to the back).

This will prevent accidents resulting from collisions with persons, other construction equipment, ledges of buildings, cables or other objects.

Driving route The route must be along 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 area of the tyres must be increased using packing made of a stable material (e.g. wooden planks).

Risk of damage to tyres Check the pressure in the tyres before moving the rigged truck crane.

The truck crane may be moved only if tyre pressures are at the prescribed GMK 7450 operating instructions – Part 1 Driving – Technical data levels Tyres.

On no account should you reduce the tyre pressure!

à

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Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

8.6.2

Rigging modes for moving and axle loads The truck crane may only be moved under certain circumstances. A part of the counterweight must be unrigged depending on the counterweight and the main boom and lattice extension must be moved to a specific position.

The tables on the following pages provide an overview of the possible settings.

S 1100

Risk of damage to the axle lines!

Always move the truck crane to the prescribed rigging mode before you drive the rigged truck crane. Positions that deviate from the rigging mode cause impermissible loads on the axle lines.

• Set the current rigging mode on the SLI, the corresponding SLI code from the Lifting capacity table must be displayed.

• Set down the load; with the exception of the hook block, which is given in the following table, no load may be lifted.

• Derrick the main boom to 81°; à p. 8 - 19.

• Derrick the luffing jib into telescoping range; à p. 8 - 20.

• Completely retract the main boom to the telescoping status 0/0/0/0;

à p. 8 - 20.

One of the following tables shows the required rigging mode for the procedure with the current luffing jib. The rigging mode is defined by: – – – – – –

the position of the superstructure the counterweight combination the telescoping the main boom angle the luffing jib angle the position of the MWL

• Check which rigging mode components have to be modified for driving and proceed as follows:

• Slew the superstructure into the position required (0° to the rear or 180° to the front).

• Lock the superstructure. The Turntable locking status display must show the symbol for the Locked setting in green.

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!

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MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

If counterweight parts need to be unrigged:

G

The following conditions must be met for the procedure in this section: – the superstructure is positioned in the required position (0° to the rear or 180° to the front) – the main boom is raised to about 81° – the main boom is fully retracted (0/0/0/0) Risk of overturning in other rigging modes Always check if the listed prerequisites are fulfilled and enter the SLI rigging code for Telescoping (or Derricking) according to the following table, before you unrig the counterweight sections.

After unrigging, the truck crane is in a rigging mode that can only be monitored by this rigging code.

This rigging code can only be accepted if the listed prerequisites are fulfilled.

• On the SLI display, enter the counterweight combination that is to be unrigged (e. g. 40 t (88 100 lbs)).

• On the SLI display, enter the current rigging mode of the lattice extension: – the length and angle position (e.g. 43 m (141 ft) and 0°) – MWL operation when MWL is raised – a main boom angle of 81° Setting the SLI, p. 8 - 17.

à

8323

• On the SLI display, enter the Telescoping rigging code for the currently rigged lattice extension (e.g. 8323 for rigged 43 m luffing jib and 40 t (88 100 lbs) counterweight combination).

• Remove the relevant counterweight parts with an auxiliary crane. Proce-

à

Operating instructions Part 2 – Crane operation, chapdure for unrigging; ter Rigging work – section Removing and putting down counterweight sections while auxiliary hoist is mounted.

27.09.2004

s

MWL Operating instructions GMK 7450

2 084 909 en

8 - 31

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

When it is necessary to extend main boom telescoping:

& 8323

G

• Switch on the Telescopic extension operating mode.

• On the SLI display, enter the Telescoping rigging code for the currently rigged lattice extension (e.g. 8323 for rigged 43 m (141 ft) luffing jib and 40 t (88 100 lbs) counterweight combination).

Danger of accidents due to incorrectly set or overridden SLI. For the rigging modes that are given in the following tables, telescoping is only monitored if the respective SLI rigging code is entered for Telescoping.

Do not enter any other SLI code and do not bridge the SLI.

• Telescope the main boom as required according to the following tables (e.g. 88/0/0/0). Prerequisite for telescoping;

à p. 8 - 20.

If main booms or luffing jibs have to be derricked:

%

Switch to Luffing jib operation.

8523

On the SLI display, enter the Derricking rigging code for the currently rigged lattice extension (e.g. 8523 for rigged 43 m (141 ft) luffing jib and 40.0 t (88 100 lbs) counterweight combination).

G

Danger of accidents due to incorrectly set or overridden SLI For the rigging modes that are given in the following tables, derricking the main boom is only monitored if the respective SLI rigging code is entered for Derricking.

Do not enter any other SLI code and do not bridge the SLI.

• Derrick the main boom to the required angle according to the following tables (e.g. 60°).

• Derrick the luffing jib to the required angle according to the following ta-

27.09.2004

bles (e.g. 45°).

8 - 32

2 084 909 en

MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

Notes on the tables

All of the axle loads in the following tables refer to a driving mode with the basic unit and on the boom extension 40 t hook block (88 200 lbs) reeved on the luffing jib; larger hook blocks must be unreeved.

The following footnotes apply in all tables: 1) Boom position to the rear = 0° position, boom over rear edge of the chassis Boom position at the front = 180° position, boom over driver's cab 2) Axle load to the front: on the first, second and third axle lines Axle load to the rear:

25 m (82 ft)-Luffing jib

on the fourth, fifth, sixth and seventh axle lines

Observe the information contained in section Notes on the tables; p. 8 - 33. There, you will also find information about footnotes 1) and 2).

à

over 40 (88.1)

Main boom position1)

8 320

Inclination of lattice extension in °

raised (90°)

Axle load2) in t (x 1000 lbs)

Inclination of main boom in °

88 / 88 / 0 / 0

Derricking

set down

Rigging code for Telescoping

Telescoping tele. I/II/III/IV/V

40 (88.1)

Position of the MWL

Counterweight in t (lbs x 1000)

Table for luffing jib with an angle position of 0°

60

45

front

17.5 (38.6)

27.5 (60.6)

60

45

front

16.5 (36.4)

28.0 (61.7)

8 520

88 / 88 / 0 / 0

front

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 40 t (88 100 lbs).

27.09.2004

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MWL Operating instructions GMK 7450

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8 - 33

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

31 m (102 ft)-Luffing jib

Observe the information contained in section Notes on the tables;

à p. 8 - 33. There, you will also find information about footnotes 1) and 2).

over 40 (88.1)

Main boom position1)

8 321

Inclination of lattice extension in °

raised (90°)

Axle load2) in t (x 1000 lbs)

Inclination of main boom in °

88 / 44 / 0 / 0

Derricking

set down

Rigging code for Telescoping

Telescoping tele. I/II/III/IV/V

40 (88.1)

Position of the MWL

Counterweight in t (lbs x 1000)

Table for luffing jib with an angle position of 0°

60

45

front

17.0 (37.5)

28.0 (61.7)

60

45

front

19.0 (41.9)

26.5 (58.4)

8 521

88 / 88 / 0 / 0

front

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 40 t (88 100 lbs).

37 m (121 ft)-Luffing jib

Observe the information contained in section Notes on the tables;

à p. 8 - 33. There, you will also find information about footnotes 1) and 2).

Main boom position1)

8 322

Inclination of lattice extension in °

88 / 44 / 0 / 0

Axle load2) in t (x 1000 lbs)

Inclination of main boom in °

raised (90°)

Derricking

88 / 44 / 0 / 0

Telescoping

set down

Rigging code for

60

45

front

19.5 (43.0)

26.0 (57.3)

60

45

front

19.0 (41.9)

27.0 (59.5)

8 522

front

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 40 t (88 100 lbs).

27.09.2004

over 40 (88.1)

Telescoping tele. I/II/III/IV/V

40 (88.1)

Position of the MWL

Counterweight in t (lbs x 1000)

Table for luffing jib with an angle position of 0°

8 - 34

2 084 909 en

MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

43 m (141 ft)-Luffing jib

Observe the information contained in section Notes on the tables;

à p. 8 - 33. There, you will also find information about footnotes 1) and 2).

over 40 (88.1)

Main boom position1)

8 323

Inclination of lattice extension in °

raised (90°)

Axle load2) in t (x 1000 lbs)

Inclination of main boom in °

88 / 0 / 0 / 0

Derricking

set down

Rigging code for Telescoping

Telescoping tele. I/II/III/IV/V

40 (88.1)

Position of the MWL

Counterweight in t (lbs x 1000)

Table for luffing jib with an angle position of 0°

60

45

front

19.5 (43.0)

26.5 (58.4)

60

45

front

18.5 (40.8)

27.5 (60.6)

8 523

88 / 0 / 0 / 0

front

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 40 t (88 100 lbs).

49 m (161 ft)-Luffing jib

Observe the information contained in section Notes on the tables; p. 8 - 33. There, you will also find information about footnotes 1) and 2).

à

über 40 (88.1)

Main boom position1)

front

rear

8 324

Inclination of lattice extension in °

raised (90°)

Axle load2) in t (x 1000 lbs)

Inclination of main boom in °

88 / 0 / 0 / 0

Derricking

set down

Rigging code for Telescoping

Telescoping tele. I/II/III/IV/V

40 (88.1)

Position of the MWL

Counterweight in t (lbs x 1000)

Table for luffing jib with an angle position of 0°

60

45

front

18.0 (39.7)

28.0 (61.7)

60

45

front

21.5 (47.4)

25.5 (56.2)

8 524

88 / 0 / 0 / 0

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 40 t (88 100 lbs).

27.09.2004

s MWL Operating instructions GMK 7450

2 084 909 en

8 - 35

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

55 m (180 ft)-Luffing jib

Observe the information contained in section Notes on the tables;

à p. 8 - 33. There, you will also find information about footnotes 1) and 2).

über 40 (88.1)

8 325

Main boom position1)

44 / 0 / 0 / 0

Inclination of lattice extension in °

raised (90°)

Axle load2) in t (x 1000 lbs)

Inclination of main boom in °

44 / 0 / 0 / 0

Derricking

set down

Rigging code for Telescoping

Telescoping tele. I/II/III/IV/V

40 (88.1)

Position of the MWL

Counterweight in t (lbs x 1000)

Table for luffing jib with an angle position of 0°

60

45

front

21.5 (47.4)

25.5 (56.2)

60

45

front

20.5 (45.2)

26.5 (58.4)

8 525

front

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 40 t (88 100 lbs).

61 m (200 ft)-Luffing jib

Observe the information contained in section Notes on the tables;

à p. 8 - 33. There, you will also find information about footnotes 1) and 2).

Inclination of lattice extension in °

Main boom position1)

8 326

Axle load2) in t (x 1000 lbs)

Inclination of main boom in °

raised (90°)

Derricking

0/0/0/0

Telescoping

set down

Rigging code for

60

45

front

20.0 (44.1)

27.0 (59.5)

60

45

front

19.0 (41.9)

27.5 (60.6)

8 526

0/0/0/0

front

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 40 t (88 100 lbs).

27.09.2004

über 40 (88.1)

Telescoping tele. I/II/III/IV/V

40 (88.1)

Position of the MWL

Counterweight in t (lbs x 1000)

Table for luffing jib with an angle position of 0°

8 - 36

2 084 909 en

MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

67 m (220 ft)-Luffing jib

Observe the information contained in section Notes on the tables;

à p. 8 - 33. There, you will also find information about footnotes 1) and 2).

über 40 (88.1)

Main boom position1)

8327

Inclination of lattice extension in °

raised (90°)

Axle load2) in t (x 1000 lbs)

Inclination of main boom in °

0/0/0/0

Derricking

set down

Rigging code for Telescoping

Telescoping tele. I/II/III/IV/V

40 (88.1)

Position of the MWL

Counterweight in t (lbs x 1000)

Table for luffing jib with an angle position of 0°

60

45

front

22,5 (49,6)

25,0 (55,1)

60

45

front

21,5 (47,4)

26,0 (57,3)

8527

0/0/0/0

front

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 40 t (88 100 lbs).

73 m (240 ft)-Luffing jib

Observe the information contained in section Notes on the tables; p. 8 - 33. There, you will also find information about footnotes 1) and 2).

à

Main boom position1)

8 328

Inclination of lattice extension in °

0/0/0/0

Axle load2) in t (x 1000 lbs)

Inclination of main boom in °

raised (90°)

Derricking

0/0/0/0

Telescoping

set down

Rigging code for

60

30

front

23.0 (50.7)

25.0 (55.1)

60

30

front

22.0 (48.5)

25.5 (56.2)

8 528

front

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 40 t (88 100 lbs).

27.09.2004

über 40 (88.1)

Telescoping tele. I/II/III/IV/V

40 (88.1)

Position of the MWL

Counterweight in t (lbs x 1000)

Table for luffing jib with an angle position of 0°

MWL Operating instructions GMK 7450

2 084 909 en

8 - 37

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

27.09.2004

Blank page

8 - 38

2 084 909 en

MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

8.6.3

Driving the rigged crane

Checking the superstructure lock

4

When driving with a rigged crane, the superstructure must be locked to the Operating instructions GMK 7450 – Locking/unlocking the turntable. carrier;

à

• Check if the symbol for the Locked position is shown in green on the Crane control display in the Superstructure lock submenu.

• Retract the outrigger cylinders until the wheels are just above the ground.

Retracting the outriggers

G

Risk of overturning Make sure that the truck crane does not overturn while the outrigger cylinders are being retracted.

Retract all the outrigger cylinders as uniformly as possible.

Switching over the suspension locking system

u

• Switch off the suspension locking system. To do this, push in the Suspension locking system rocker switch at the top. The suspension locking system indicator lamp must extinguish.

All wheels are now lowered to the ground.

• Retract the outrigger cylinders so far that the truck crane is located on a level where there is still enough room to move in both directions.

u

G

• Switch the suspension locking system back on again. To do this, push the Suspension locking system rocker switch at the bottom. The Suspension locking system indicator lamp lights up as soon as the suspension system is locked.

• Continue to retract the outrigger cylinders.

Risk of overturning when switching off the suspension locking system As long as the truck crane is on wheels, you may not turn off the suspension locking system for any reason. The suspension is no longer under pressure and when the suspension locking system is switched off, the suspension struts would be pressed together, damaged and the truck crane could tip over.

27.09.2004

s MWL Operating instructions GMK 7450

2 084 909 en

8 - 39

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

G

Risk of overturning To reduce the risk of the crane overturning do not raise the outrigger pads more than 5 to 10 cm (2 to 4 in) off the ground. Leave the outrigger beams extended.

Driving

S S H

Risk of damage to tyres Check the pressure in the tyres before moving the rigged truck crane.

The truck crane may only be moved if the tyre pressures are at the preOperating instructions GMK 7450 – Checking the tyres. Do scribed levels; not reduce the tyre pressure.

à

Risk of damaging the steering linkage Steer the truck crane only when the vehicle is moving. The steering linkage can be damaged if the steering is turned while the vehicle is stationary.

Check the wind speed before moving the rigged truck crane. The same maximum permitted wind speeds apply for moving the truck crane as for workOperating instructions GMK 7450 - Influence of wind on ing with the crane; crane operation.

à

• Switch the transfer case to off-road gear to move the truck crane; à Operating instructions GMK 7450 – Off-road gear.

]

• Select first gear as the starting gear and also select first gear as the highest possible gear; à Operating instructions GMK 7450 – Operating the automatic transmission – starting and Driving and changing gears.

• Drive as slowly as possible!

• The radius should be as large as possible when turning corners.

• Steer the truck crane only while it is moving and avoid sudden steering movements.

27.09.2004

When the surface is uneven the truck crane must be raised with the outrigger cylinders, horizontally aligned and then re-lowered.

8 - 40

2 084 909 en

MWL Operating instructions GMK 7450

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

Supporting the truck crane

G If necessary, rig the counterweight sections

Before beginning crane work, support the truck crane with the outrigger Operating instrucspan required for the planned use of the truck crane; tions GMK 7450 – Outriggers.

à

Risk of overturning The truck crane must be raised until no wheels touch the ground.

If you have rigged the counterweight sections before moving, you have to now rig these sections again.

• On the SLI display, enter the counterweight combination that is to be rigged (e.g. 120 t (264 500 lbs)).

• Rig the relevant counterweight parts with an auxiliary crane. Procedure

à

27.09.2004

Operating instructions Part 2 – crane operation, chapter Rigfor rigging; ging work – section Removing and putting down counterweight sections while auxiliary hoist is mounted.

MWL Operating instructions GMK 7450

2 084 909 en

8 - 41

Operation with the luffing jib and the MWL 8.6 Driving with rigged crane, rigged luffing jib and rigged MWL

27.09.2004

Blank page

8 - 42

2 084 909 en

MWL Operating instructions GMK 7450

9 9

Operation with heavy load lattice extension and MWL

9.1

Further rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

3

Rigging for operation with heavy load lattice extension . . . . . . . . . . . . . . . . . . 9 Unrigging after operation with the heavy load lattice extension . . . . . . . . . . . 9 Extra information on positioning the hoist rope with rigged MWL. . . . . . . . . . 9 -

3 3 4

Operation with braced boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

5

CHECKLIST: Bringing the boom system into operating condition . . . . . . . . . . 9 CHECKLIST: Bringing the boom system into the rigging mode . . . . . . . . . . . . 9 Setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

5 6 7

Operation with MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

9

9.1.1 9.1.2 9.1.3 9.2 9.2.1 9.2.2 9.2.3 9.3 9.3.1 9.3.2

Bringing the boom system into the operating condition . . . . . . . . . . . . . . . . . . 9 - 9 Bringing the boom system into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . 9 - 11

9.4

Rigging mode with unbraced boom system and raised MWL . . . . . . . . . . . . . . . 9 - 13

9.5

Turning loads with the heavy load lattice extension. . . . . . . . . . . . . . . . . . . . . . . 9 - 15

9.5.1 9.5.2 9.5.3 9.6

Prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16 Set SLI for turning the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17 Turning a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22 Rigging modes for moving and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22 Driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26

27.09.2004

9.6.1 9.6.2 9.6.3

MWL Operating instructions GMK 7450

2 084 909 en

27.09.2004

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL

9

Operation with heavy load lattice extension and MWL

G

Risk of accidents if the safety information is ignored.

For operation with the heavy load lattice extension and MWL, all warnings given in the GMK 7450 lattice extension operating instructions also apply.

This chapter merely supplements the GMK 7450 lattice extension operating instructions through the addition of information necessary when operating the heavy load lattice extension together with the MWL.

In the following sections there is information on the further procedure for operating with the heavy load lattice extension and the MWL after the MWL has been rigged.

– The section Further rigging work contains information on further rigging work specifically for operation with the heavy load lattice extension and the MWL, and on preparations for unrigging.

– The section Operation with braced boom system contains all the information required to set the SLI, telescope with rigged MWL as well as for folding in and out and bracing the boom system.

– The section Operation with MWL set down contains all the information required to operate the heavy load lattice extension when the MWL is rigged but neither raised nor braced.

27.09.2004

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

MWL Operating instructions GMK 7450

2 084 909 en

9-1

Operation with heavy load lattice extension and MWL

27.09.2004

Blank page

9-2

2 084 909 en

MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.1 Further rigging work

9.1

Further rigging work

9.1.1

Rigging for operation with heavy load lattice extension 1. The MWL was rigged in accordance with the chapter MWL – Rigging and unrigging; CHECKLIST: Rigging the MWL, p. 5 - 5.

à

2. Rig the heavy load lattice extension required as described in the GMK 7450 lattice extension operating instructions. To position the hoist Extra information on positioning the hoist rope with rigged MWL, rope; p. 9 - 4.

à

3. Reeve the main hoist rope on the heavy load lattice extension; p. 9 - 4.

à

4. Bring the boom system into the operating condition required: – For operation with braced boom system; – For operation with MWL set down;

9.1.2

à p. 9 - 5

à p. 9 - 9.

Unrigging after operation with the heavy load lattice extension 1. Bring the boom system into the rigging mode required: – After operation with braced boom system; – After operation with MWL set down;

1100

à p. 9 - 6

à p. 9 - 11.

2. The current rigging mode for operation with the heavy load lattice extension is entered on the SLI.

3. Rig the heavy load lattice extension as described in the GMK 7450 heavy load lattice extension operating instructions; GMK 7450 lattice extension operating instructions – Heavy load lattice extension – CHECKLIST: Unrig the heavy load lattice extension.

27.09.2004

à

4. To continue unrigging the MWL; p. 5 - 10.

MWL Operating instructions GMK 7450

2 084 909 en

à CHECKLIST: MWL – unrigging,

9-3

Operation with heavy load lattice extension and MWL 9.1 Further rigging work

9.1.3

Extra information on positioning the hoist rope with rigged MWL With rigged MWL and rigged heavy load lattice extension, the main hoist rope must not be rigged on the heavy load lattice extension.

If the heavy load lattice extension is to be used to turn loads, the auxiliary p. 9 - 15. hoist rope must be reeved on the heavy load lattice extension;

S

à

Risk of damage to the auxiliary hoist rope Only ever reeve the main hoist rope on the heavy load lattice extension. If the auxiliary hoist rope is reeved on the heavy load lattice extension, the auxiliary hoist rope will be at an impermissible angle and will therefore be damaged.

• Guide the main hoist rope (1) on the raising frame (2) over the right-hand deflection sheave.

To position the hoist rope on the deflection sheaves (3), (4) and (5), proceed as for operation without MWL; GMK 7450 lattice extension operating instructions – Boom extension – Positioning and reeving the hoist rope.

à

Only for turning loads:

• Guide the main hoist rope (6) on the raising

27.09.2004

frame (2) over the right-hand deflection sheave.

9-4

2 084 909 en

MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.2 Operation with braced boom system

9.2

Operation with braced boom system This section only describes operation with heavy load lattice extension and braced boom system, which enables increased lifting capacity.

S 9.2.1

For operation with rigged but unraised MWL; down, p. 9 - 9.

à Operation with MWL set

Risk of damage to the auxiliary hoist rope Only ever reeve the main hoist rope on the heavy load lattice extension. If the auxiliary hoist rope is reeved on the heavy load lattice extension, the auxiliary hoist rope will be at an impermissible angle and will therefore be damaged.

CHECKLIST: Bringing the boom system into operating condition

H 1100

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.

1. Select the actual rigging mode for operation with heavy load lattice extension and MWL on the SLI, or set the corresponding SLI code accordSetting the SLI, p. 9 - 7. ing to the Lifting capacity table;

à

2. Telescope the main boom to the telescoping required for operation according to the Lifting capacity table. Telescoping takes place in the same way as for operation with the main boom without heavy load lattice exTelescoping with rigged MWL, p. 6 - 14. tension;

à

3. Fold out both gantry masts. Folding out takes place in the same way as for operation with the main boom without heavy load lattice extension; Folding the gantry masts out/in, p. 6 - 15.

à

4. Derrick the main boom to the bracing angle required and brace the boom system. Derricking and bracing takes place in the same way as for operation with the main boom without heavy load lattice extension; Brace the boom system, p. 6 - 17.

27.09.2004

à

MWL Operating instructions GMK 7450

2 084 909 en

9-5

Operation with heavy load lattice extension and MWL 9.2 Operation with braced boom system

9.2.2

CHECKLIST: Bringing the boom system into the rigging mode

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.

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

1100

2. The current rigging mode for operation with the heavy load lattice exSetting the SLI, p. 9 - 7. tension and MWL is entered on the SLI;

à

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

4. To unlock the MWL, derrick the main boom to the bracing angle; Derricking to the bracing angle, p. 6 - 17.

à

à Folding the gantry masts out/in, p. 6 - 15.

Retract the main boom completely; à Telescoping with rigged MWL,

5. Fold in the gantry masts; 6.

p. 6 - 14.

7. Slew the superstructure into the position for unrigging (preferably to the rear) and lower the main boom to the horizontal.

à Unrigging after operation with the

27.09.2004

8. To continue unrigging the MWL; heavy load lattice extension, p. 9 - 3.

9-6

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.2 Operation with braced boom system

9.2.3

Setting the SLI On the SLI, a rigging mode for the truck crane with a heavy load lattice extension that is also permissible for operation with the MWL is entered first Operating instructions GMK 7450 – Part 2 Crane (to enter the rigging mode operation - Crane operation).

Afterwards, the MWL is entered for this rigging mode.

à

The Enter rigging mode submenu shows the rigging mode entered, e.g.: – Counterweight combination 120 t (264 500 lbs) – Heavy load lattice extension 7.5 m (25 ft), 42° – Outrigger span 8.76 x 8.90 m (28.7 x 29.2 ft) – Slewing range ±180°.

The SLI code display (3) shows the corresponding SLI code, e.g. 1862.

The Current boom system display (1) shows a truck crane with heavy load lattice extension.

• Press the button beside the symbol Enter MWL (2) once. The button next to the symbol is only active when the MWL is raised to 90°.

H

If it is not permissible to operate the MWL with the rigging mode shown, there will be no change on the display.

If operation with the MWL is permissible with the rigging mode shown: – the symbol Enter MWL (2) is highlighted in green – the Current boom system display (1) shows a truck crane with heavy load lattice extension and MWL – the SLI code display (3) shows the corresponding SLI code for operation with MWL, e.g. 3862.

27.09.2004

• Accept the rigging mode selected (2x Ö ).

s MWL Operating instructions GMK 7450

2 084 909 en

9-7

Operation with heavy load lattice extension and MWL 9.2 Operation with braced boom system

The submenu SLI monitoring now shows the selected rigging mode with MWL. The Maximum load display (1) shows the load of the rigging curve for the current rigging mode according to the Lifting capacity table, e.g.

5.0 t (11 000 lbs).

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The SLI will only enable the increased lifting capacity for operation with MWL when the MWL is braced.

9-8

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.3 Operation with MWL set down

9.3

Operation with MWL set down This section only describes operation with the heavy load lattice extension and MWL set down. The boom system is not braced and increased lifting capacity will not be enabled.

S 9.3.1

Risk of damage to the hoist rope!

When the MWL is set down, only operation with the main hoist is permitted. If the main hoist rope is led over the right-hand rope sheave on the raising frame, the hoist rope runs at an impermissible angle and could cause damage, causing the load to fall.

Bringing the boom system into the operating condition This section presumes that the MWL is rigged as described in the checklist Rigging the MWL for operation with MWL set down.

If previously operated with the boom system braced, check that the following conditions are met.

– The guy ropes are removed from the lateral head sheaves and are lying, lightly taut, on the brackets on the gantry masts; Removing the guy rope, p. 5 - 62.

à

– The MWL is set down on the main boom;

à MWL – setting down, p. 5 - 71.

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9-9

Operation with heavy load lattice extension and MWL 9.3 Operation with MWL set down

Setting the SLI

For operation with the MWL set down, you must enter the current rigging mode for operation with the heavy load lattice extension without MWL on the SLI.

• Enter the current rigging mode.

For operation with MWL set down: – the Current boom system display (1) must show a truck crane with heavy load lattice extension and without MWL – the SLI code display (3) must show an SLI code for operation with the main boom, e.g.

1862.

• Accept the rigging mode selected (2x Ö ).

The symbol Input MWL (2) is shown in light grey when the MWL is set down and the button next to the symbol is not active.

The SLI now takes into account the Lifting capacity table corresponding to the SLI code displayed for operation with the heavy load lattice extension.

When the MWL is set down, the values specified in the Lifting capacity tables are reduced.

The decreased values are shown directly in the Maximum load display (1).

To calculate these values for operation planning, there are corresponding formulas and examples in the Lifting capacity tables in the chapter Notes.

H

The display Maximum load (1) only shows the reduced values when the MWL is connected electrically. Otherwise, the values from the lifting capacity tables will be shown – however, the reduced values still apply for shutdown of the system.

à Malfunctions on the SLI, p. 10 - 7.

27.09.2004

If error messages occur;

9 - 10

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.3 Operation with MWL set down

Telescoping

G Operation with the heavy load lattice extension

9.3.2

Telescoping with MWL set down is done in the same way are for operation with heavy load lattice extension without MWL. Risk of damage to the lateral head sheaves and guy ropes.

Make sure that the guy ropes have been removed from the lateral head sheaves before telescoping the main boom with the MWL set down. In this way you prevent damage to the lateral head sheaves or the guy ropes during telescoping.

Operation of the power units when working with the heavy load lattice extension with MWL set down is the same as for working with the heavy load GMK 7450 lattice extension operating inlattice extension without MWL; structions – Heavy load lattice extension.

à

Bringing the boom system into the rigging mode Operation of the power units when working with MWL set down is the same as for working with the heavy load lattice extension without MWL; GMK 7450 lattice extension operating instructions – Heavy load lattice extension.

à

This section assumes the following: – the truck crane is supported with the outrigger span required for the previous job, and aligned to the horizontal – the actual rigging mode for operation with the heavy load lattice extension is entered on the SLI.

• Set down the load.

• Fully retract the main boom.

• Slew the superstructure into the position for unrigging (preferably to the rear) and lower the main boom to the horizontal.

à Unrigging after operation with the heavy

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To continue unrigging the MWL; load lattice extension, p. 9 - 3.

MWL Operating instructions GMK 7450

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9 - 11

Operation with heavy load lattice extension and MWL 9.3 Operation with MWL set down

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Blank page

9 - 12

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.4 Rigging mode with unbraced boom system and raised MWL

9.4

Rigging mode with unbraced boom system and raised MWL The rigging mode with rigged heavy load lattice extension, raised MWL and unbraced boom system is not for use when telescoping.

As long as the MWL is unbraced, the SLI only enables the lifting capacity of the empty hook curve. There are no lifting capacity tables for this rigging mode; therefore, it is not permissible to raise loads in this rigging mode.

27.09.2004

G

Risk of overturning in an impermissible operating mode when SLI is overridden.

Operation with the heavy load lattice extension is not permitted with the MWL raised and the boom system unbraced.

Do not on any account override the SLI in order to raise loads in this mode whose weight exceeds the values of the empty hook curve.

This prevents the truck crane from overturning.

MWL Operating instructions GMK 7450

2 084 909 en

9 - 13

Operation with heavy load lattice extension and MWL 9.4 Rigging mode with unbraced boom system and raised MWL

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Blank page

9 - 14

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

9.5

Turning loads with the heavy load lattice extension Two-hook operation is required for turning loads. Two-hook operation with the MWL is also permitted with the heavy load lattice extension (additional equipment).

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.

H

à

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 disregarded, accidents can 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 (heavy load lattice extension) first.

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G G

It is only possible to turn loads when the MWL is raised. When the MWL is set down, you can only bring the deflection sheave for the main hoist rope p. 5 - 52. into the Operating position on the raising frame;

MWL Operating instructions GMK 7450

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9 - 15

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

9.5.1

Prerequisites The following description requires that – The MWL is raised and braced – The main boom is at the telescoping required – The gantry masts have been folded out – The main hoist rope is reeved on the main boom

Risk of damage to the hoist rope When you reeve the main hoist rope on the main rope and reeve the auxiliary hoist rope on the heavy load lattice extension, the hoist ropes will rub against each other and the auxiliary hoist rope will be at an impermissible angle. This will result in damage to both hoist ropes.

Risk of accidents due to overloading The reeving on the main boom must be equal to or greater than that on the lattice extension!

The auxiliary hoist rope and the auxiliary hoist will become overloaded if this condition is not met.

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S G

– The auxiliary hoist rope on the heavy load lattice extension is reeved

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

9.5.2

Set SLI for turning the load You must use the SLI for two-hook operation: – Enter the current reeving for the main and auxiliary hoist The values are stored and called up directly when switching hoists.

– Switch on operation with both hoists in such a way that the digit for the main hoist lights up on the Hoists indicator lamp.

Entering a reeving

You can enter the reeving for both hoists at any time, indepedent of which hoist is switched on.

When the Enter reeving symbol (1) is shown without digits on the Reeving display, you must switch on input mode first:

• Press the button once next to the symbol (1).

The symbol (1) will be highlighted in green and input mode is switched on.

A digit also now appears beside the symbol, e.g. I. This digit shows which hoist the displayed reeving applies to: Digit I: Main hoist Digit II:

Auxiliary hoist

• In the Reeving display (2), enter the current number of runs of the reeved hoist rope for the hoist shown (89), e.g. 09, for the main hoist.

• Press the button next to the symbol Enter reeving (1) repeatedly until the digit for the other hoist is shown (e.g. II for the auxiliary hoist).

• In the Reeving display (2), enter the current number of runs of the reeved hoist rope for this hoist (89), e. g. 02 for the auxiliary hoist.

In this way the reevings are entered for both hoists.

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MWL Operating instructions GMK 7450

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9 - 17

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

Set the SLI to the auxiliary hoist

äå ä

The SLI always takes into account the reeving entered for the hoist which is displayed at the Hoists indicator lamps. To turn loads, the SLI must take the main hoist and its reeving into account and both hoists must be switched on. This SLI setting can be reached in the following way:

• Switch off both hoists.

To do this, press down the Main hoist on/off and Auxiliary hoist on/off rocker switches once.

Indicator lamps in the rocker switches are dimly lit.

• Now 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.

At the Hoists indicator lamps, lamp I for the main hoist lights up.

å

• Switch on the auxiliary hoist.

Press the Auxiliary hoist on/off rocker switch down once. The indicator lamp in the rocker switch lights up brightly.

At the Hoists indicator lamps, lamp II for the auxiliary hoist now lights up as well.

1100

• On the SLI, select the current rigging mode with the rigged heavy load lattice extension and MWL or enter the appropriate SLI code according to Setting the SLI, p. 9 - 7. the Lifting capacity table;

à

The SLI is thus set for two-hook operation, it now takes into account: – The reeving for the main hoist – The lifting capacity tables for the heavy load lattice extension.

• Brace the boom system. Otherwise, only the rigging program loads for the current rigging modes given in the Lifting capacity table will be enabled.

9 - 18

27.09.2004

H

In two-hook operation, the load measurement is taken using the pressure in the derricking cylinder. The loads detailed in the Lifting capacity table then decrease by the weight of both reeved hook blocks.

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

9.5.3

Turning a load

G H H

Carry out the load turning only as it is described in this section.

Risk of accidents due to overloading!

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

For this reason, 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 concerning SLI shutdown are on the safe side.

During the entire lifting operation, the rigging mode with the heavy load lattice extension must be entered on the SLI and displayed.

• First, only sling the load to the hook block of the heavy load lattice extension (rope of the auxiliary hoist).

• Lift the load completely off the ground with the heavy load lattice extension.

• Only now should you attach the load to the

27.09.2004

hook block of the main boom as well (main hoist rope).

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9 - 19

Operation with heavy load lattice extension and MWL 9.5 Turning loads with the heavy load lattice extension

• Now lift the load with the hook block on the main boom until both slinging points are at the same height.

• Slacken the hoist rope on the heavy load lattice extension until the load is only hanging from the hook block on the main boom.

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Turning the load has now been completed.

9 - 20

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

9.6

Driving with rigged crane and rigged heavy load lattice extension with rigged MWL This section describes how to move the truck crane with an installed counterweight, rigged heavy load lattice extension and rigged MWL.

H

Risk of accidents You must not 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 brake must be engaged.

Risk of accidents when you cannot see the entire truck crane While driving the rigged truck crane, always stay in visual or radio contact with a banksman who additionally observes the parts which you cannot see (e.g. the raised boom in cases where the superstructure is turned to the back).

This will prevent accidents resulting from collisions with persons, other construction equipment, ledges of buildings, cables or other objects.

27.09.2004

G G G

When driving with a rigged heavy load lattice extension, always switch on the separate steering and do not steer if stationary.

MWL Operating instructions GMK 7450

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9 - 21

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

9.6.1

S 9.6.2

Driving route The route must be along 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 area of the tyres must be increased using packing made of a stable material (e.g. wooden planks).

Risk of damage to tyres Check the pressure in the tyres before moving the rigged truck crane.

The truck crane may be moved only if tyre pressures are at the prescribed GMK 7450 operating instructions – Part 1 Driving – Technical data levels Tyres.

On no account should you reduce the tyre pressure!

à

Rigging modes for moving and axle loads The truck crane may only be moved under certain circumstances. A part of the counterweight must be unrigged depending on the counterweight and the main boom and lattice extension must be moved to a specific position.

The tables on the following pages provide an overview of the possible settings.

S Bringing the truck crane into the rigging mode

Risk of damage to the axle lines!

Always move the truck crane to the prescribed rigging mode before you drive the rigged truck crane. Positions that deviate from the rigging mode cause impermissible loads on the axle lines.

One of the following tables shows the required rigging mode for the procedure for the currently rigged heavy load lattice extension. The rigging mode is defined by: the position of the MWL the angle position of the heavy load lattice extension the counterweight combination the position of the superstructure the telescoping the main boom angle

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– – – – – –

9 - 22

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MWL Operating instructions GMK 7450

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

• Set down the load; with the exception of the hook block, which is given in the following table, no load may be lifted.

• If applicable, set down the MWL as well; à Setting down the MWL, p. 5 - 57.

• If necessary, set the required angle position of the heavy load lattice ex-

à

Lattice extension operating instructions GMK 7450 – Heavy load tension; lattice extension.

• On the SLI display, enter the current counterweight combination or the counterweight combination that is to be unrigged (e.g. 80 t (176 300 lbs)).

• On the SLI display, enter the current rigging mode of the lattice extension: – The length and angle position of the rigged heavy load lattice extension (e.g. 7.5 m (25 ft) and 42°) – MWL operation when MWL is raised

• If necessary, use an auxiliary crane for unrigging in order to obtain the re-

à

Operatquired counterweight combination – procedure for unrigging; ing instructions Part 2 – Crane operation, chapter Rigging work – section Removing and putting down counterweight sections while auxiliary hoist is mounted.

• Slew the superstructure into the position required (0° to the rear or 180° to the front).

!

• Lock the superstructure. The Turntable locking status display must show the symbol for the Locked setting in green.

• Derrick the main boom to the required angle for telescopic extension. You can find the required main boom angle in the Lifting capacity table, in the chapter Rigging tables for heavy load lattice extension.

• Telescope the main boom to the required telescoping and lock the telescopic sections.

• Derrick the main boom to the position required.

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9 - 23

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

All of the axle loads in the following table refer to a driving mode with the basic unit and with a 40 t hook block reeved on the heavy load lattice extension; larger hook blocks must be unreeved.

Inclination of main boom in °

Main boom position1)

front

0/0/0/0

15

front

11.5 (25.4)

23.0 (50.7)

0/0/0/0

82

rear

9.5 (21.0)

24.5 (54.0)

0/0/0/0

15

front

13.0 (28.7)

21.5, (47.4)

0/0/0/0

82

rear

11.5 (25.4)

23.0 (50.7)

88 / 0 / 0 / 0

15

front

17.0 (37.5)

23.5 (51.8)

0/0/0/0

82

rear

13.5 (29.8)

26.5 (58.4)

88 / 0 / 0 / 0

15

front

19.0 (41.9)

22.5 (49.6)

0/0/0/0

82

rear

15.5 (34.2)

24.5 (54.0)

88 / 88 / 44 / 0

15

front

22.0 (48.5)

25.0 (55.1)

0/0/0/0

82

rear

17.5 (38.6)

28.0 (61.8)

88 / 88 / 0 / 0

15

front

21.5 (47.4)

25.5 (56.2)

0/0/0/0

82

rear

20.0 (44.1)

26.5 (58.4)

set down 20 raised (90°)

set down 40 (88 100)

20 raised (90°)

set down 60 (132 200)

20 raised (90°)

80, 100, 120, 140, 160 1) 2)

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 60 t (132 200 lbs).

Boom position to the rear =

0° position, boom over rear edge of the chassis

Boom position at the front =

180° position, boom over driver's cab

Axle load to the front:

on the first, second and third axle lines

Axle load to the rear:

on the fourth, fifth, sixth and seventh axle lines

9 - 24

rear

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MWL Operating instructions GMK 7450

27.09.2004

20 (44 000)

Axle load2) in t (x 1 000 lbs)

Telescoping Telescopic section I/II/III/IV

Position of the MWL

Inclination of lattice extension in °

Rigged counterweight in t (lbs)

4 m (13 ft)-heavy load lattice extension

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

All of the axle loads in the following table refer to a driving mode with the basic unit and with a 40 t hook block reeved on the heavy load lattice extension; larger hook blocks must be unreeved.

Inclination of main boom in °

Main boom position1)

front

0/0/0/0

15

front

12.5 27.6

22.5 49.6

0/0/0/0

82

rear

9.0 (19.9)

25.0 (55.1)

0/0/0/0

15

front

14.5 (32.0)

21.0 (46.3)

0/0/0/0

82

rear

11.5 (25.4)

23.5 (51.8)

88 / 0 / 0 / 0

15

front

19.0 (41.9)

22.5 (49.6)

0/0/0/0

82

rear

13.5 (29.8)

27.0 (59.5)

88 / 0 / 0 / 0

15

front

20.5 (45.2)

21.5 (47.4)

0/0/0/0

82

rear

15.5 (34.2)

25.0 (55.1)

88 / 88 / 0 / 0

15

front

22.0 (48.5)

25.5 (56.2)

88 / 44 / 0 / 0

82

front

19.5 (43.0)

27.0 (59.5)

0/0/0/0

82

rear

19.5 (43.0)

27.0 (59.5)

set down 20 (44 000)

20 raised (90°)

set down 40 (88 100)

20 raised (90°)

60 (132 200)

set down 20 raised (90°)

80, 100, 120, 140, 160 1)

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2)

Axle load2) in t (x 1 000 lbs)

Telescoping Telescopic section I/II/III/IV

Position of the MWL

Inclination of lattice extension in °

Rigged counterweight in t (lbs)

7,5 m (25 ft)-heavy load lattice extension

rear

Driving with rigged truck crane not permitted.

Unrig the counterweight combination to 60 t (132 200 lbs).

Boom position to the rear =

0° position, boom over rear edge of the chassis

Boom position at the front =

180° position, boom over driver's cab

Axle load to the front:

on the first, second and third axle lines

Axle load to the rear:

on the fourth, fifth, sixth and seventh axle lines

MWL Operating instructions GMK 7450

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9 - 25

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

9.6.3

Driving the rigged crane

Checking the superstructure lock

4 Retracting the outriggers

G

When driving with a rigged crane, the superstructure must be locked to the Operating instructions GMK 7450 – Locking/unlocking the turntable. carrier;

à

• Check if the symbol for the Locked position is shown in green on the Crane control display in the Superstructure lock submenu.

• Retract the outrigger cylinders until the wheels are just above the ground.

Risk of overturning Make sure that the truck crane does not overturn while the outrigger cylinders are being retracted.

Retract all the outrigger cylinders as uniformly as possible.

Switching over the suspension locking system

u

• Switch off the suspension locking system. To do this, push in the Suspension locking system rocker switch at the top. The suspension locking system indicator lamp must extinguish.

All wheels are now lowered to the ground.

• Retract the outrigger cylinders so far that the truck crane is located on a level where there is still enough room to move in both directions.

G G 9 - 26

• Switch the suspension locking system back on again. To do this, push the Suspension locking system rocker switch at the bottom. The Suspension locking system indicator lamp lights up as soon as the suspension system is locked.

• Continue to retract the outrigger cylinders.

Risk of overturning when switching off the suspension locking system As long as the truck crane is on wheels, you may not turn off the suspension locking system for any reason. The suspension is no longer under pressure and when the suspension locking system is switched off, the suspension struts would be pressed together, damaged and the truck crane could tip over.

Risk of overturning To reduce the risk of the crane overturning do not raise the outrigger pads more than 5 to 10 cm (2 to 4 in) off the ground. Leave the outrigger beams extended.

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MWL Operating instructions GMK 7450

27.09.2004

u

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

Driving

S S H

Risk of damage to tyres Check the pressure in the tyres before moving the rigged truck crane.

The truck crane may only be moved if the tyre pressures are at the preOperating instructions GMK 7450 – Checking the tyres. Do scribed levels; not reduce the tyre pressure.

à

Risk of damaging the steering linkage Steer the truck crane only when the vehicle is moving. The steering linkage can be damaged if the steering is turned while the vehicle is stationary.

Check the wind speed before moving the rigged truck crane. The same maximum permitted wind speeds apply for moving the crane as for working Operating instructions GMK 7450 – Influence of wind on crane with the crane; operation.

à

• Switch the transfer case to off-road gear to move the truck crane; à Operating instructions GMK 7450 – Off-road gear.

]

• Select first gear as the starting gear and also select first gear as the high-

à

Operating instructions GMK 7450 – Operating the autoest possible gear; matic transmission – starting and Driving and changing gears.

• Drive as slowly as possible!

• The radius should be as large as possible when turning corners.

• Steer the truck crane only while it is moving and avoid sudden steering movements.

When the surface is uneven the truck crane must be raised with the outrigRetracting the ger cylinders, horizontally aligned and then re-lowered; outriggers, p. 9 - 26 and Switching over the suspension locking system, p. 9 - 26.

à

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MWL Operating instructions GMK 7450

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9 - 27

Operation with heavy load lattice extension and MWL 9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL

Supporting the truck crane

G If necessary, rig the counterweight sections

Before beginning crane work, support the truck crane with the outrigger Operating instrucspan required for the planned use of the truck crane; tions GMK 7450 – Outriggers.

à

Risk of overturning The truck crane must be raised until no wheels touch the ground.

If you have rigged the counterweight sections before moving, you have to now rig these sections again.

• On the SLI display, enter the counterweight version that is to be rigged (e.g. 80 t (132 200 lbs)).

• Rig the relevant counterweight parts with an auxiliary crane. Procedure

à

27.09.2004

Operating instructions Part 2 – crane operation, chapter Rigfor rigging; ging work – section Removing and putting down counterweight sections while auxiliary hoist is mounted.

9 - 28

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MWL Operating instructions GMK 7450

10 10

Malfunctions during operation with the MWL

10.1

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

2

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

2

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

3

10.1.1 10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.3

10 10 10 10 -

3 6 7 9

Operation with emergency program switched on . . . . . . . . . . . . . . . . . . . . . . . . 10 - 19 Operating the MWL in the emergency program . . . . . . . . . . . . . . . . . . . . . . . . 10 - 19 Telescoping in the emergency program with a rigged MWL. . . . . . . . . . . . . . 10 - 22

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10.3.1 10.3.2

Malfunctions during operation with the MWL . . . . . . . . . . . . . . . . . . . . . . . . .

Malfunctions when operating with the hand-held control . . . . . . . . . . . . . . . .

Malfunctions on the SLI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error messages on the crane control display . . . . . . . . . . . . . . . . . . . . . . . . . .

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Malfunctions during operation with the MWL

10

Malfunctions during operation with the MWL The information in this chapter only relates to truck cranes which are equipped for operation with the MWL. It supplements the chapter Malfunctions during crane operation in the GMK 7450 operating instructions with the following points: – Electrical system – Troubleshooting – Error messages on the SLI display

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– Error messages on the Crane control display

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10 - 1

Malfunctions during operation with the MWL 10.1 Electrical system

10.1

Electrical system

10.1.1

Fuses In the distributor box on the right-hand side at the turntable there is an extra fuse group.

• Loosen the retaining bolts and take off the cover from the distributor box (1).

The fuse group F 7 is for the electrical system of the MWL. The following tables show the designations of the individual fuses, including strength and function.

The designations 1 to 6 in the tables correspond to the order from top to bottom (fuse 1 is always the top fuse).

Designation in circuit diagram: F 7

Strength (A)

Function

20

Control unit on connection 5

2

3

Control unit on connection 5

3

2

Not assigned

4

5

Control unit on connection 5/ Power supply for shaft encoder Lefthand/right-hand winch

5

10

Not assigned

6

20

Not assigned

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1

10 - 2

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MWL Operating instructions GMK 7450

Malfunctions during operation with the MWL 10.2 Troubleshooting

10.2

Troubleshooting

10.2.1

Malfunctions during operation with the MWL

H

All functions of the MWL are disabled as a general rule when a load other than the hook block is raised, or when operation with MWL has not been selected on the SLI.

Malfunction

Cause

Remedy

The submenu MWL – Operation cannot be activated from the main menu.

The MWL is not electrically connected. The symbol Submenu MWL – Operation is shown in light grey.

Check if the electrical connection is connected properly; p. 5 - 39.

The current program version of the crane control is not equipped for operation with MWL. The symbol Submenu MWL – Operation is not shown.

The crane control requires another program version; inform GROVE Customer Support.

The supply line to the control unit on connection 5 (in the right-hand gantry mast) has been broken, or the control unit on connection 5 is defective.

Check the supply line as necessary and inform GROVE Customer Support.

No function: Locking/unlocking the winches Winding/unwinding the winches, Raising/setting down the MWL Folding the gantry masts out/in

The hydraulic or electrical connections are not connected properly.

Connect the hydraulic connection ( p. 5 - 36) and the electrical connection ( p. 5 - 39) properly.

Winches cannot be unlocked

A load other than the hook block is raised.

Set down the load.

Winches cannot be locked

The boom system is braced, the winches are already locked.

Winches cannot be wound or unwound

The winches are locked.

à p. 5 - 65 or à p. 5 - 75

The MWL cannot be raised

The gantry mast and the holding frame are still connected.

Release the connection between the gantry mast and the holding frame; p. 5 - 51.

à

à

à

Unlock the winches;

à

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The connection between the raising frame and the main boom is broken.

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2 084 909 en

Connect the raising frame and the main boom; p. 5 - 45.

à

s 10 - 3

Malfunctions during operation with the MWL 10.2 Troubleshooting

The MWL cannot be set down

The boom system is braced.

à p. 5 - 65 or à p. 5 - 75

The gantry masts are not folded in completely.

Fold in the gantry masts p. 5 - 78 completely; or p. 6 - 15

The main boom is at an angle over 5°.

Derrick the main boom to an angle under 5°

The boom system is braced.

à p. 5 - 65 or à p. 5 - 75

The MWL is not raised to the end position 90°.

Raise the MWL to the end position 90°; p. 5 - 56.

The maximum permissible rope force was exceeded because the winches are locked.

Unlock the winches; p. 5 - 65 or p. 5 - 75

The following functions are disabled and the corresponding displays show the error message in purple:

There is a logic error, e.g. the end states are reported as being locked and unlocked simultaneously,

GROVE Customer Support should be notified

– Locking/unlocking the winches (c d)

or there is an electrical error at the corresponding proximity switches.

à

The gantry masts cannot be folded out or in.

Unlock the winches;

à

à

Unlock the winches;

à

à

à

If necessary, unrig the MWL with emergency program; p. 10 - 19

– Folding the gantry masts in/ out (l n) – MWL Raising/ setting down MWL (m).

The main boom cannot be telescoped.

The main boom cannot be derricked, the Derricking gear display shows a red arrow

One or both gantry masts are not folded in completely:

Fold in the gantry masts completely; p. 6 - 15.

One or both winches are unlocked:

Locking the winches; p. 6 - 19:

The MWL is not raised to the end position 90°.

Raise the MWL to the end position 90°; p. 5 - 56.

The MWL is in an intermediate position (p).

Bring MWL into the Raised to 90° position (X) or into the Placed under 5° position (q); p. 5 - 70, p. 5 - 71.

à

à

à

à

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à

10 - 4

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MWL Operating instructions GMK 7450

Malfunctions during operation with the MWL 10.2 Troubleshooting

MWL cannot be braced.

The main boom is at an impermissible telescoping.

Bring the main boom into a telescoping position which is permitted for operation with the MWL; Lifting capacity table.

à

The main boom is not at the required bracing angle.

Derrick the main boom to the bracing angle shown on the Bracing angle set value display; p. 6 - 17.

à

The telescoping mechanism does not meet all the requirements for bracing

Check the following and correct if necessary: The telescopic sections are locked.

The telescoping cylinder is locked.

The telescopic section has been set down.

The MWL is not raised to the end position 90°.

Raise the MWL to the end position 90°; p. 5 - 56.

The gantry masts are not folded in or out completely.

Fold out the gantry masts completely; p. 6 - 15.

Operation with MWL has not been selected on the SLI.

Select operation with MWL on the SLI; p. 6 - 11.

The bracing procedure was not completed. The bracing status display shows the error symbol in purple (k).

During the bracing procedure an error was detected, and the procedure was aborted as a result.

Unlock the winches and repeat the bracing procedure.

If the error occurs again, contact GROVE Customer Support.

The SLI shuts down due to overload even though the maximum lifting capacity according to the Lifting capacity chart has not been exceeded.

Operation with MWL has not been selected on the SLI.

Select operation with MWL on the SLI; p. 6 - 11.

The MWL is raised but the boom system is not braced.

à p. 6 - 17.

During operation with MWL set down, operation with MWL is still selected on the SLI.

Select operation without MWL on the SLI; p. 6 - 11.

à

à

à

à

Brace the boom system;

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à

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10 - 5

Malfunctions during operation with the MWL 10.2 Troubleshooting

10.2.2

Malfunctions when operating with the hand-held control The following malfunction table applies to both hand-held controls.

Malfunction

Cause

Remedy

Indicator lamp CAN flashes or stays off after the hand-held control is connected

The bridging plug has been unplugged at another socket.

Plug in the bridging plug and secure it with collar nut; Operating instructions GMK 7450 – Part 2 Crane operation – Rigging work – Description of the truck crane – Handheld control.

Malfunction in the control system

GROVE Customer Support should be notified

Fuse F 2/3 OW defective

Check the fuses and replace if necessary; Operating instructions GMK 7450 – Part 2 Crane operation – Malfunctions during crane operation – Electrical system.

The Crane control emergency stop switch or the emergency stop switch on the hand-held control is depressed.

à

à Operating instructions

GMK 7450 – Part 2 Crane operation – Malfunctions during crane operation – Emergency shut-off devices on the superstructure

Another function is selected

Preselect desired function

Malfunction in the control system

GROVE Customer Support should be notified

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Preselected function cannot be carried out

à

10 - 6

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MWL Operating instructions GMK 7450

Malfunctions during operation with the MWL 10.2 Troubleshooting

10.2.3

Malfunctions on the SLI This section only shows those error messages and suggestions for remedies which apply to truck cranes equipped for operation with the MWL. If Operating instructions GMK 7450 – Malfuncother error messages occur; tions during crane operation – Troubleshooting and rectification on the SLI.

à

When an error occurs, the Error message submenu shows the following: – The corresponding error code (2) (e.g.

1.25.1) – The corresponding symbols (3) to (5) on the Error definition display.

– The location of the error, indicated by the corresponding red marking flashing (1).

The table which follows does not contain all possible error codes. If other error codes are displayed, then these are errors that necessitate contacting GROVE Customer Support.

Error group 1, sensor system Error code/ error definition display

Cause

Remedy

à

1.

25.

1

Sensor A not reacting (load cell Left-hand winch)

p. 10 - 8.

Check the supply line; If supply line is OK, notify GROVE Customer Support

1.

25.

2

Measured values are no longer updated

Switch the ignition off and then on again; if error is displayed again, notify GROVE Customer Support.

1.

25.

6

Error in the data transmission

Switch ignition off and back on again, Check the supply line; p. 10 - 8; if the error is shown again, GROVE Customer Support should be notified

à

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10 - 7

Malfunctions during operation with the MWL 10.2 Troubleshooting

Error group 1, sensor system Error code/ error definition display

Cause

Remedy

à

1.

26.

1

Sensor B not reacting (load cell Right-hand winch)

p. 10 - 8.

Check the supply line; If supply line is OK, notify GROVE Customer Support

1.

26.

2

Measured values are no longer updated

Switch the ignition off and then on again; if error is displayed again, notify GROVE Customer Support.

1.

26.

6

Error in the data transmission

Switch ignition off and back on again, Check the supply line; p. 10 - 8; if the error is shown again, GROVE Customer Support should be notified

Check the supply line

à

The load cell sensors are located on the winches.

1 Plug connection for sensor A, right-hand winch 2 Plug connection for sensor B, right-hand winch

• To check the lines, follow the lines from the

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plug connections to the sensors or vice versa.

10 - 8

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MWL Operating instructions GMK 7450

Malfunctions during operation with the MWL 10.2 Troubleshooting

10.2.4

Error messages on the crane control display This section only shows those error messages and suggestions for remedies which apply to truck cranes equipped for operation with the MWL. The error messages are shown on the Crane control display, just as for operation without GMK 7450 operating instructions – the MWL; Error messages on the crane control display.

à

The symbols at the positions (2) and (4) are shown in exactly the same way as for operation without the MWL, and have the same meaning.

At the position (1) and (3) for the faulty device there are two symbols which can only be displayed for operation with the MWL. The tables in the following sections show the symbols of the devices and the indices when operating with MWL for the error code (5).

H

If further error messages are shown which are not listed in the following tables Error messages on the or in the tables in the GMK 7450 operating instructions ( crane control display), please contact your local GROVE Customer Support.

à

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10 - 9

Malfunctions during operation with the MWL 10.2 Troubleshooting

Symbols for additional devices

The following table shows all the additional symbols for faulty devices when operating with MWL which may be displayed at position 1 for the various devices.

Device

Device number

Control unit at connection 5

6

Angle sensor 1, Mega Wing Lift Left winch (additional equipment)

26

Angle sensor 2, Mega Wing Lift Right winch (additional equipment)

27

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Symbol

10 - 10

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MWL Operating instructions GMK 7450

Malfunctions during operation with the MWL 10.2 Troubleshooting

Allocation of the additional index displays

The following table shows additional displays for the index of a group when operating with MWL, which are shown at position 3.

Table for the allocation of the index for analogue inputs of the control unit

Symbol for group

Symbol for device

S2613P S2614P

Index

NC NC

#4

NC NC Socket recognition Socket recognition

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10 - 11

Malfunctions during operation with the MWL 10.2 Troubleshooting

Table for the allocation of the index for digital inputs of the control unit Symbol for group

Symbol for device

S2601N S2602N S2603N S2604N

#4

NC S2606N S2607N

Index

NC S2609N S2610N S2611N S2612 NC NC

NC

10 - 12

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MWL Operating instructions GMK 7450

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NC

Malfunctions during operation with the MWL 10.2 Troubleshooting

Table for the index allocation for digital outputs of the control unit Symbol for group

Symbol for device

Y3409 Y3410 Y2615 Y2616

#4

Y2603

Index

Y2604 Y2605 Y2606 Y2607 Y2608 Y2609 Y2610 Y2611

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10 - 13

Malfunctions during operation with the MWL 10.2 Troubleshooting

Symbol for group

Symbol for device

Y2612

Index

Y2602, Y2613 Y2601, Y2614 NC

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Vcc-Perm

10 - 14

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MWL Operating instructions GMK 7450

Malfunctions during operation with the MWL 10.2 Troubleshooting

Table for the index allocation for FAKEs (digital inlets which are used as an output) Symbol for group

Symbol for device

OUT OUT OUT OUT

#4

OUT OUT

Index

OUT NC OUT OUT OUT OUT OUT OUT OUT

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10 - 15

Malfunctions during operation with the MWL 10.2 Troubleshooting

Symbol for group

Symbol for device

Index

OUT NC OUT

Table for the allocation of the index for analogue and digital inputs of the input/output circuit boards

à

GMK 7450 opThere are no additional symbols for operation with MWL; erating instructions – Error messages on the crane control display.

Table for the index allocation for digital outputs of the input/output circuit boards

à

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GMK 7450 opThere are no additional symbols for operation with MWL; erating instructions – Error messages on the crane control display.

10 - 16

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MWL Operating instructions GMK 7450

Malfunctions during operation with the MWL 10.2 Troubleshooting

Error messages via the Can bus

The table in this section shows the error messages for individual devices when operating with MWL when these can no longer be reached via the CAN bus.

Boby .

Symbol for Device

Symbol of the group

Index number

Error type number

0 to 2 valid

0 to 6

0 to 2 valid

0 to 6

0 and 1

0 and 1

Cause/possible remedy

Switch the ignition off and then back on again; if the error reoccurs: – Use the hand-held control to rig the truck crane; GMK 7450 operating instructions – Malfunctions during crane operation – Emergency operation in case of failure of the operating instruments in the crane cab – or – After consultation with GROVE Customer Support, replace the control unit at connection 0; GMK 7450 operating instructions – Malfunctions during crane operation – Unrigging the truck crane in the event of a defective control unit.

à

à

0 and 1

Angle sensor 1, Left-hand winch cannot be reached via the CAN bus, either after switching on the ignition (Index 1) or during operation (Index 0).

The functions Lock winches, Lock left-hand winch and Brace are disabled. In the submenus, the corresponding symbols are shown in grey.

The current crane job cannot be completed.

However, it is no longer possible to rebrace. After completing the crane job, rectify the error.

0 and 1

Angle sensor 2, Right-hand winch cannot be reached via the CAN bus, either after switching on the ignition (Index 1) or during operation (Index 0).

The functions Lock winches, Lock right-hand winch and Brace are disabled. In the submenus, the corresponding symbols are shown in grey.

The current crane job can be completed. However, it is no longer possible to rebrace. After completing the crane job, rectify the error.

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10 - 17

Malfunctions during operation with the MWL 10.2 Troubleshooting

System monitoring group error messages

Symbol for device

Symbol of the group

The table in this section shows the error displays concerning system monitoring for operation with MWL.

Index number

Error type number

Cause/possible remedy

1

Check whether the earth cable on the control unit of the connection displayed is fastened; GMK 7450 operating instructions – Malfunctions during crane operation – Replacing control units.

2, 4, 6, 7 or 9

Switch the ignition off and then on again; if the error is displayed again, notify GROVE Customer Support.

8

GROVE Customer Support should be notified and the control unit at the connection shown replaced if necessary; GMK 7450 operating instructions – Malfunctions during crane operation – Replacing control units.

10

Check the fuse for the control unit at the connection displayed and replace if necessary; GMK 7450 – Malfunctions during crane operation – Fuses in the crane cab.

à

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0

à

10 - 18

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MWL Operating instructions GMK 7450

Malfunctions during operation with the MWL 10.3 Operation with emergency program switched on

10.3

Operation with emergency program switched on With rigged MWL the Telescoping emergency program can be switched on. This emergency program is intended for two cases: – For unrigging the MWL, when the MWL cannot be operated due to an electrical error (e.g. when the Folded out message is detected with folded in gantry masts – then the MWL can no longer be set down).

– For unrigging the truck crane, when the telescoping mechanism can only be operated in the emergency program due to an electrical error.

In both cases, special conditions apply. For this reason, observe the information in the following chapter before calling up the emergency program.

10.3.1

Operating the MWL in the emergency program

l Switching on the emergency program

S

If it is no longer possible to operate the MWL due to an electrical error, in most cases a purple symbol is shown for an error (e.g. the symbol on the Left-hand gantry mast display).

In this case, you can only control some functions of the MWL by switching on the Telescoping emergency program.

The emergency program is switched on in the same way as when operating without MWL and is described here in a shortened form. For more detailed Operating instructions GMK 7450 – Part 2 Crane operation – information; Chapter Malfunctions during crane operation – Emergency operations and emergency programs.

à

Risk of damage when emergency program is switched on!

Be sure that all necessary requirements are fulfilled before you perform a function in the emergency program. The crane control is not monitored.

All functions are carried out immediately and unconditionally.

• If another menu is shown on the Crane control display, press the Exit submenu/entry mode button (

ö) until the main menu is displayed.

• In the main menu, press the button next to the symbol Submenu for settings/status display (1).

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s MWL Operating instructions GMK 7450

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10 - 19

Malfunctions during operation with the MWL 10.3 Operation with emergency program switched on

The display changes to the Settings/displays submenu.

• Press the right dead man’s switch and keep it pressed in.

• Press the switch near the symbol Telescoping emergency program access (1).

On the display Actual status telescoping mechanism (2), the input prompt appears.

• Press the Input key code button (3) in the following sequence:

ÆÅÆÇ When you have entered the correct key code, the display (2) now shows the symbol for the Emergency program status (v).

The emergency program stays switched on for about 360 seconds.

S H

Danger of damage to the telescoping mechanism!

If there is no malfunction at the telescoping mechanism, then wait until the time is up and the emergency program is ended before you telescope the main boom. In the emergency program the telescoping mechanism is not monitored by the crane control and you can execute functions that would damage the telescoping mechanism.

When you end the emergency program by switching off the ignition, you have to reenter the telescope diagram after restarting; Operating instructions GMK 7450.

à

• Switch to the Operation-MWL submenu (ö – 1).

As long as the emergency program is switched on, the Emergency program display (2) is shown in this submenu and in the Rigging-MWL submenu.

The functions are only released, the Bracing status display shows the symbol (1) in grey (not braced).

Unlock winches (G) once.

The symbol (1) is now shown in grey and the functions are released in the emergency program.

10 - 20

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MWL Operating instructions GMK 7450

27.09.2004

• When the symbol (1) in shown in green, press the button near the symbol

Malfunctions during operation with the MWL 10.3 Operation with emergency program switched on

Operating the MWL

When the emergency program is switched on, the MWL can only be set down very slowly.

In the submenu Operation – MWL The symbol Brace boom system (2) is shown in light grey. The button next to the symbol is not active.

The button under the symbols (4) are not active for the teleautomation.

The function of the button next to the symbols (3) remains unchanged when folding the gantry masts in and out.

Locking and unlocking is done by pressing the button next to the symbols (1). Since the crane control does not carry out any additional functions in the emergency program, you have manually support the process, if needed.

gh gihj

– If unlocking is not carried out, you have to switch to the Rigging-MWL submenu and wind the winch somewhat to relieve the locking units.

– If locking is not carried out, you have to switch to the Rigging-MWL submenu and wind the winches in or out so that the teeth of the locking unit can engage.

In the submenu Rigging – MWL The function of the button next to the symbols (3) remains unchanged when raising or setting down the gantry masts.

The function of the button next to the symbols (2) remains unchanged when winding and unwinding the winches.

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Locking and unlocking is done by pressing the button next to the symbols (1). Support this process in the same way as in the OperationMWL submenu.

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10 - 21

Malfunctions during operation with the MWL 10.3 Operation with emergency program switched on

10.3.2

Telescoping in the emergency program with a rigged MWL

S

Risk of damage when emergency program is switched on!

Authoritative for the operation of the telescoping mechanism in the emergency program are all specifications and safety instructions in the supplied Operating instructions GMK 7450 – Part 2 Crane opoperating instructions; eration – Chapter Malfunctions during crane operation – Emergency operations and emergency programs.

This section only contains additional information that must be observed when the MWL is rigged before telescoping in the emergency program.

à

The Telescoping emergency program is switched on in the same way as durSwitching on the emergency program, ing operation without MWL; p. 10 - 19.

à

• Observe the following points about the specifications in the accompanying Operating instructions before telescoping in the emergency program:

When retracting

G gh

Extending

When retracting in the emergency program, the winches on the gantry masts do not automatically follow. In this way, the guy ropes remain relieved and sag.

Danger from slack rope.

Pay attention that the guy ropes do not slacken to the point where there is slack rope when winding.

• When retracting, pay attention to the guy ropes. In this case, interrupt retracting promptly and wind up the winches on the gantry masts until the guy ropes are taut again.

Carry out the Extending function in the emergency program only if it is absolutely necessary. Since the winches on the gantry masts do not automatically follow, the guy ropes become taut.

The following safety shutdown procedure is used to avoid overloading the guy ropes.

When extending, the current rope forces are monitored. As soon as the maximum permissible rope force has been reached, the crane control switches the extension off. In this case, you have to unwind the winches until the guy ropes slacken a bit, then extension is released again.

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gh

10 - 22

2 084 909 en

MWL Operating instructions GMK 7450

11 11

Maintenance work on the MWL

11.1

Modules in need of protection during cleaning work . . . . . . . . . . . . . . . . . . . . . 11 -

1

11.2

Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

3

11.2.1 11.2.2 11.2.3 11.2.4 11.2.5

11 11 11 11 11 -

3 4 4 5 5

11.3

Lubricant table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

7

11.4

Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

9

Changing the guy ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20

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11.4.12

Maintenance plan D: daily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance plan W: weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 3 maintenance plan: Every 3 months / after 300 oper. hrs. . . . . . . . . . . . . .

M 6 maintenance plan: every 6 months / after 500 oper. hrs. . . . . . . . . . . . . .

M 12 maintenance plan: every 12 months / after 1000 oper. hrs. . . . . . . . . . .

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Maintenance work on the MWL 11.1 Modules in need of protection during cleaning work

11

Maintenance work on the MWL

11.1

Modules in need of protection during cleaning work

• Provide protection for the following electrical parts during cleaning work: – the plug connections (1) for the load cells on the winches – the control unit (3) on connection 5 (opening at the bottom of the gantry mast) – the diagnostics plug (5) – the connecting cable (7) and its plugs (6) in the dummy sockets – the proximity switch (4) – the plug connection (2) for the rotary transducer of the left-hand winch 27.09.2004

– all electrical plug connections.

H

Also observe all instructions contained in the chapter titled Cleaning work of the Maintenance instructions of the GMK 7450.

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11 - 1

Maintenance work on the MWL 11.1 Modules in need of protection during cleaning work

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MWL Operating instructions GMK 7450

Maintenance work on the MWL 11.2 Maintenance plans

11.2

Maintenance plans

H 11.2.1

All the general notes, safety rules and information on environmental protection contained in Chapters 1 and 2 of the GMK 7450 Maintenance instructions apply when carrying out this maintenance work.

The following maintenance plans apply in addition to the maintenance plans with the same name given in the GMK 7450 Maintenance instructions.

The same abbreviations are used as in the GMK 7450 Maintenance instructions (e.g. oper. hrs. = operating hours).

Maintenance plan D: daily

D Maintenance work on the SUPERSTRUCTURE: daily

Oil / lubricant Amount (l) (gal)/ Quantity

MWL – Position of the rope on winch drum and sheaves;

Designation p. 11 - 3

à

à p. 11 - 9.

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s

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11 - 3

Maintenance work on the MWL 11.2 Maintenance plans

11.2.2

Maintenance plan W: weekly

W Maintenance work on the SUPERSTRUCTURE: weekly

Oil / lubricant Amount (l) (gal)/ Quantity

Designation p. 11 - 3

à

MWL

à p. 11 - 10.

Check the winch gears for leaks; à p. 11 - 11.

Check the oil level at the winch gears; à p. 11 - 11.

Lubricate the joints of the holding frame1); à p. 11 - 13.

Check the rope end fittings of the guy ropes2); à p. 11 - 15.

– Check the lateral head sheaves; – – – –

1) 2)

11.2.3

E3 2

K

at least each time before putting into operation If the MWL is in storage only, the condition check is only necessary every three months.

M 3 maintenance plan: Every 3 months / after 300 oper. hrs.

M Maintenance work on the SUPERSTRUCTURE: every 3 months / after 300 oper. hrs

Oil / lubricant Amount (l) (gal)/ Quantity

Designation p. 11 - 3

– Lubricating the winch gears; p. 11 - 15.

2

K

– Lubricate the gear rim;

2

V

à

MWL

à p. 11 - 17.

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à

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MWL Operating instructions GMK 7450

Maintenance work on the MWL 11.2 Maintenance plans

11.2.4

M 6 maintenance plan: every 6 months / after 500 oper. hrs.

M6 Maintenance work on the SUPERSTRUCTURE: every 6 months / after 500 oper. hrs

MWL – Checking the condition of the truck crane;

11.2.5

Oil / lubricant Amount (l) (gal)/ Quantity

Designation p. 11 - 3

à

à p. 11 - 15.

M 12 maintenance plan: every 12 months / after 1000 oper. hrs.

M 12 Maintenance work on the SUPERSTRUCTURE: every 12 months / after 1000 oper. hrs

MWL – Oil change at the winch gear1); – Lubricate the locking units1);

à p. 11 - 18.

Amount (l) (gal)/ Quantity

Designation p. 11 - 3

for each 0.75 (0.2)

E6

2

K

à

Carry out at least once a year

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1)

à p. 11 - 19.

Oil / lubricant

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11 - 5

Maintenance work on the MWL 11.2 Maintenance plans

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MWL Operating instructions GMK 7450

Maintenance work on the MWL 11.3 Lubricant table

11.3

Lubricant table

H

The lubricants listed in the following table are to be used in the maintenance of the MLW.

Designation

Lubricating point

Type of lubrication

E 61)

Transmission

Circulatory lubrication

K

Roller bearing

For repairs, use with grease

V

Open-running gear wheels

Adhesive lubrication

Lubricant type Viscosity range

C - LPF

MIL-L 2105B API-GL4/5

SAE 75 W-90 ISO-VG 220

KP - L2K

DIN 51825

GROVE part no. 0554 2053)

Synthetic oil filled at the factory; do not mix with mineral oil.

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1)

Specification Classification

Designation according to DIN 51502

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11 - 7

Maintenance work on the MWL 11.3 Lubricant table

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MWL Operating instructions GMK 7450

Maintenance work on the MWL 11.4 Maintenance work

11.4

Maintenance work

11.4.1

Checking the position of the guy ropes on the winch drum

T

You can only carry out the following checks with the MWL set down and the winches stationary.

G

Risk of accidents from unintentional rotation of the winch drum.

Shut down the crane engine and secure it against unauthorized use before you start work on the winch drums. The rotating winch drum can inflict serious crushing injuries!

• Check the position of the guy rope (1) on the winch drum – The rope must be wound evenly on the drum.

– The turns on the drum must all be at an equal distance of between 0 to 2 mm (0.08 inch).

– The cross-over points must be at an angle of approx. 180°.

The upper rope lines lie over the lower rope lines at the cross-over points.

• Check the position of the guy rope on the

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other winch in the same way.

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11 - 9

Maintenance work on the MWL 11.4 Maintenance work

11.4.2

W

Checking the lateral head sheaves • Secure the lateral head sheave (1);

à p. 5 - 66.

• Unwind the guy rope (3) slightly so that the head sheave is relieved of tension and can be turned by hand.

• Check the lateral head sheave (1) for damage and wear, and check that it runs freely.

• Check the base of the groove (5). There may be no scores anywhere on the entire circumference of the base of the groove.

• Pull the guy rope slightly taut.

• Release the lateral head sheave (1);

à p. 5 - 67.

• Check to make sure all bolts (2) on the cover are tight.

• Check the tightening torque of the bolts (4) on the bearing block with 180 Nm (133 lbf ft).

• Check the lateral head sheave on the other

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side in the same way.

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MWL Operating instructions GMK 7450

Maintenance work on the MWL 11.4 Maintenance work

11.4.3

Checking the winch gears for leaks

W

• Make a visual inspection for leaks.

• If hydraulic oil or gear oil has been lost, check the oil levels and top up if necessary.

If damage cannot be rectified immediately or further damage is likely:

• Inform your local GROVE Customer Support or your repair crew.

11.4.4

Checking the oil level in the winch gears

W

In order to check the oil level, the MWL can be removed and set down, or set down on the set-down main boom. It is important that the MWL is at the horizontal for the oil level check.

• Check the oil level via the inspection glass (2). The hydraulic oil must be visible in the inspection glass.

• Check the oil level at the other winch in the same way.

If the oil level is too low:

• Top up oil via the standpipe (1).

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Use only oil specified in the Maintenance plan, p. 11 - 4.

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11 - 11

Maintenance work on the MWL 11.4 Maintenance work

11.4.5

Lubricating the joints on the holding frame

W

Each joints is lubricated via an individual lubricating nipple.

Only use lubricating grease specified in the Maintenance plan, p. 11 - 5.

H

Lubricate the joints at least each time before putting into operation. This will prevent problems occurring when rigging the MWL.

Each side of the holding frame has a lubricating nipple (1).

• Remove old grease and dirt from the grease nipples.

• Use a grease gun to lubricate the grease nipples until fresh grease comes out at the bearing point (2).

Remove the excess grease.

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Lubricate the joint on the other side of the holding frame in the same way.

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MWL Operating instructions GMK 7450

Maintenance work on the MWL 11.4 Maintenance work

11.4.6

Checking the end fastenings of the guy ropes

W

The ends of the guy ropes are fastened to the gantry masts and to the winch drums.

Check at the gantry masts

Holders and load cells are found between the guy ropes and the gantry masts. You have to check that the rope ends and the load cells are fastened properly.

Fastening the rope ends

• Check the splice clamp (4) and the guy rope close to the splice clamp for corrosion and deformation.

• Damaged parts must be replaced immediately.

The splice clamp (4) is fastened to the holder (1) with pins (3). The pin (3) is secured with a cotter pin (2).

• Check the pin (3) for corrosion and deformation.

• Check that the splint (2) fits tightly.

• Check the fastenings on the other gantry mast in the same way.

• Damaged parts must be replaced immediately.

Fastening the load cells

• Check the pins (1) for corrosion and deformation.

• Check that the splints (2) fit tightly.

• Check the fastenings on the other gantry mast in the same way.

• Damaged parts must be replaced immediately.

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11 - 13

Maintenance work on the MWL 11.4 Maintenance work

Check at the winch drums

G S

To carry out the check at the winch drums, you must move the winches.

Therefore, the MWL must be rigged and set down on the main boom for this check. The electrical and hydraulic connections must have been established.

Risk of accidents from unintentional rotation of the rope drum!

Shut down the crane engine and secure it against unauthorized use before you start work on the winch drums. The rotating winch drum can inflict serious crushing injuries!

Risk of damage and danger from slack rope!

Remove the guy rope loops from the brackets on the gantry masks before winding in the winches, and always keep the guy ropes lightly taut when winding. In this way you prevent damage to the brackets, or the formation of slack rope.

The ends of the guy ropes are fastened to the winch drums by a clamping device with 15 locking screws.

The locking screws (1) are accessible from the outside at the winch drum.

The counterscrews (2) fix a clamp rail and must not be loosened.

• Turn the winch drum until the locking screws are visible.

• Check the tightening torque of the 15 clamping screws (1) (Tightening torque = 270 Nm (221.2 lbf ft)).

You will not be able to reach all the locking screws. In order to reach all 15 locking screws, the winch must be turned further.

• Check the rope end fastening on the other winch drum in the same way.

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To reach the locking screw on the Left-hand winch you must raise the MWL slightly.

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MWL Operating instructions GMK 7450

Maintenance work on the MWL 11.4 Maintenance work

11.4.7

Lubricating the winch gears

M3

The winch gears are lubricated using a grease nipple.

Only use lubricating grease specified in the Maintenance plan, p. 11 - 4.

The grease nipple (1) is on the left-hand side of both winches, on the winch axle.

To reach the grease nipple on the Left of the winch you must raise the MWL slightly.

• Remove old grease and dirt from the grease nipples.

• Use a grease gun to lubricate the grease nipples until fresh grease comes out.

• Remove the excess grease.

Lubricate the gears on the other winch in the same way.

11.4.8

Checking the condition of the guy ropes

M6

To check the guy ropes along their entire length, the main boom must be telescoped out with the MWL rigged. The winches are then at a height of ca.

12 m (40 ft), making it necessary for you to use a raising platform or an auxiliary crane which is authorized for the transport of persons.

• Support the truck crane with the outrigger span 8.76 m x 8.90 m (28.7 x 29.2 ft).

• Rig a counterweight version which is permitted for operation with the MWL.

• On the SLI, enter the actual rigging mode for operation with the main boom and MWL;

à Setting the SLI, p. 6 - 11.

• Derrick the main boom into a working range which is permissible for the

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telescoping.

H

If in doubt about damage assessment, always consult an expert.

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11 - 15

Maintenance work on the MWL 11.4 Maintenance work

G

Risk of accidents from rotating winches.

Make sure that you do not come within range of the rotating winches. The rotating winches can inflict serious crushing injuries!

• Move a lifting platform, or other device authorized to lift persons, into the vicinity of the winch (1) whose guy rope is to be checked first.

• Slowly telescope out the main boom and, while doing so, check the guy rope along its entire length.

Information on the criteria for evaluating the condition of the rope or damage to the rope; GMK 7450 maintenance manual – Hoist ropes – Assessing the condition of the hoist ropes.

à

• Check the guy rope on the other winch in the same way.

The following table indicates at what amount of wire breaks the rope must be changed.

H Load-bearing outer wires 141 - 160

G

The specifications in the table only apply to the original rope!

Regular lay rope (diameter 33 mm (1.3 in)) on 6 x d (198 mm (7.8 in) length)

on 30 x d (990 mm (39.0 in) length)

6

13

Risk of accidents from falling loads!

The guy rope must not be shortened. If the rope is shortened, there will no longer be the required number of safety turns on the winch drum when the main boom is fully extended. Without safety turns, the guy rope may slip out of the clamping device on the winch drum during operation.

Damage to the boom system and dropping of the load could result.

à Changing the guy ropes, p. 11 - 20.

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If the rope needs to be changed;

11 - 16

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Maintenance work on the MWL 11.4 Maintenance work

11.4.9

M3

Lubricating the gear rim

On the gear rimes, the grease is applied to the gear teeth directly (brushed on or sprayed).

Only use special grease as specified in the Maintenance plan, p. 11 - 5.

H

G S

Observe the instructions and safety information on the grease packaging.

Risk of crushing if the winches are operated inadvertently.

Shut down the crane engine and secure it against unauthorized use before you lubricate the gear rims. In this way you prevent being crushed by the rotating gear rim or flapping locking element.

Risk of damage and danger from slack rope!

Remove the guy rope loops from the brackets on the gantry masks before winding in the winches, and always keep the guy ropes lightly taut when winding. In this way you prevent damage to the brackets, or the formation of slack rope.

The gear rims (2) are located on the right-hand sides of both winches and can be reached from above and below. You will not be able to reach the entire gear rim.

• Apply the special grease to the entire area of both gear rims (2).

To reach the teeth behind the locking element (1), you can unlock the winch.

• Roll up the winch in order to lubricate the gear rim in its entirety. To do this, take the rope loop out of the holders on the gantry masts.

• Lubricate the gear rim on the other winch in the same way.

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• Lock both winches after lubricating.

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11 - 17

Maintenance work on the MWL 11.4 Maintenance work

11.4.10

M 12

Lubricating the locking units

Each locking unit has two grease nipples for lubrication.

Only use lubricating grease specified in the Maintenance plan, p. 11 - 5.

G

Risk of crushing if the winches are operated inadvertently.

Shut down the crane engine and secure it against unauthorized use before you lubricate the gear locking unit. In this way you prevent being crushed by the rotating gear rim or flapping locking element.

The grease nipples (1) are located on the bearing points of the hydraulic cylinders of the locking units.

• Remove old grease and dirt from the grease nipples.

• Use a grease gun to lubricate the grease nipples until fresh grease comes out.

Remove the excess grease.

• Lubricate the locking unit on the other winch

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in the same way.

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MWL Operating instructions GMK 7450

Maintenance work on the MWL 11.4 Maintenance work

11.4.11

Changing the oil at the winch gears

M 12

In order to change the oil, the MWL can be removed and set down, or set down on the set-down main boom.

It is important that the MWL is at the horizontal for the oil change.

O

Pollution warning Always use oil collection vessels which are oil-resistant.

Wipe up spilled oil immediately.

Use only oil specified in the Maintenance plan, p. 11 - 5.

• Place an oil collection vessel under the oil drain plug (3) (capacity ca. 2 l (0.53 gal) for both winches).

• Loosen the screw plug (1) on the standpipe.

• Unscrew the oil drain plug (3) and let the oil flow into the collection container.

• Screw both of the oil drain plugs (3) back in.

Renew the seal.

• To speed up the filling process, unscrew the vent screw (4).

• Fill up with oil via the standpipe (1) until it is visible in the inspection glass (2) (centre to upper edge).

• Screw the vent screw (4) back in again with a new sealing ring.

• Close the standpipe with the screw plug (1).

Danger of damage to the environment from leaking fuel!

Collect waste oil in approved containers and have it disposed of properly.

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O

• Change the oil on the other winch in the same way.

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11 - 19

Maintenance work on the MWL 11.4 Maintenance work

11.4.12

Changing the guy ropes

H

G G

Changing the guy ropes goes beyond the normal framework of maintenance work and should therefore only be carried out by personnel with special training. This section only describes the elements on the MWL which are needed to loosen and fasten the guy ropes. This information presumes you possess the specialist knowledge required for changing the guy ropes properly without detrimental effect to their service life.

If you have any doubts, contact GROVE Customer Support.

Risk of accidents from falling loads!

Only use replacement guy ropes which have the same technical specifications as the guy ropes originally supplied. Use only authentic Grove replacement parts.

Risk of accidents from unintentional rotation of the rope drum!

Shut down the crane engine and secure it against unauthorized use before you start work on the winch drums. The rotating winch drum can inflict serious crushing injuries!

The manner in which the guy ropes are fitted can affect their service life.

Errors during fitting reduce service life considerably, therefore: – Make sure the guy ropes are not twisted when they are fitted.

– Ensure they do not get dirty or damaged while being fitted.

– Wind the guy ropes up in the same direction in which the guy rope is reeled onto the reel.

– Tense the guy ropes slightly while reeling them up.

Prerequisites

Before changing the guy ropes, the following requirements must be met: – The MWL is rigged and set down on the main boom.

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– The MWL is electrically and hydraulically connected (so that the winches can be wound up and down).

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Maintenance work on the MWL 11.4 Maintenance work

Rope end fittings on the gantry mast

H

On the gantry masts, the rope ends of the guy ropes are on the holders on the load cells.

The following diagrams show the end fastenings of the Left-hand winch. The end fastenings of the Right-hand winch are identical.

Removing the guy rope

• Unwind the winch by about 0.5 m (2.0 ft).

• Loosen the splint (2) from the pin (1).

• Remove the distance ring (4) from the pin.

• Pull the pin (1) out of the bore.

• Pull the splice clamp (3) out of the holder (5).

• Unwind the guy rope from the winch drum until only the safety turns are still on the drum.

• Now you can loosen the end fastening on the winch drum; p. 11 - 22.

à Removing the guy rope,

Fastening the guy rope

• Guide the guy rope over the deflection sheave on the head of the gantry mast and up to the winch drum.

• Fasten the guy rope to the winch drum and wind up the guy rope; rope, p. 11 - 23.

à Fastening the guy

• Insert the splice clamp (3) into the holder (5) in such a way that the bores align.

• Insert the pin (1) into the bore hole.

• Insert the the distance ring (4) into the pin on both sides.

• Fasten the splint (2) onto the pin (1) on both sides.

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11 - 21

Maintenance work on the MWL 11.4 Maintenance work

Rope end fittings on the winch drums

G

On the winch drums there are clamping devices to fasten the guy ropes.

Risk of accidents from unintentional rotation of the rope drum Shut down the crane engine and secure it against unauthorized use before you start work on the winch drums. The rotating winch drum can inflict serious crushing injuries!

Removing the guy rope

• Turn the drums until the locking screws (1) are visible.

In order to reach all 15 locking screws, the winch must be turned further.

The clamp rail is held with fixing bolts (2) which may not be loosened.

• Loosen the visible locking screw (1). Do not loosen the fixing bolts (2).

• Execute the movement Wind winch until the last locking screws are visible.

• Loosen the last locking screws (1).

• Completely unwind the guy rope and pull the guy rope (3) out from the clamping device.

• To reach the locking screws on the Right-

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hand winch you must raise the MWL slightly.

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Maintenance work on the MWL 11.4 Maintenance work

Fastening the guy rope

• Mark (1) the new guy rope with the required clamp length of 650 to 700 mm (25.6 to 27.6 in).

• Align the reel with the new guy rope in such a way that you can wind the guy rope onto the winch drum without kinks.

S S

Risk of accidents from slipping rope clamp Always push the guy rope up to the designated clamp length in the clamping device.

In this way you prevent the guy rope from slipping out of the clamping device, the main boom becoming overloaded and the load falling.

Risk of damage to the guy rope After you have pushed the guy rope into the clamping device, you should only carry out the movement Wind winch in order to reach all the locking screws. In this way you prevent damage to the guy rope from its becoming clamped between the winch drum and the winch frame.

• Push the guy rope (3) up to the mark made on the clamping device.

The rope end (2) must jut out slightly from the other side of the clamping device.

• First, tighten the locking screws (1) which you can reach. The required tightening torque = 270 Nm (221.2 lbf ft).

• Execute the movement Wind winch until the last locking screws are visible.

• First, tighten the locking screws (1) with the tightening moment required.

• The guy rope will give slightly after the first tightening. For this reason, check the tightening torque at all locking screws again.

• Wind up the guy rope so far that the rope end can be fastened to the load cell;

à Fastening the guy rope, p. 11 - 21.

• To fasten the guy rope on the Right-hand winch you must raise the MWL 27.09.2004

slightly.

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Maintenance work on the MWL 11.4 Maintenance work

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12 Index

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12

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MWL Operating instructions GMK 7450

Index

12

Index The index has the following structure: The names of parts or modules you are searching for are listed in alphabetical order on the left. The following are indented under these terms: – Operations (e.g. outrigger beam / extend) or – Sub-headings (e.g. steering / display and operating elements) or – Sub-headings in relation to operations (e.g. hydraulic system / preheat hydraulic oil).

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H

The first search word is always a noun which is followed by an operation or a subheading.

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12 - 1

Index

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12 - 2

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Index

A

Abbreviation abbreviation used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Addition to GMK 7450 operating instructions to the driving mode table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 uses that are only possible with the auxiliary hoist . . . . . . . . . . . . . . . . . . . . . . 1 - 3

B

Basic safety instructions intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9 personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11 safety instructions for truck crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13 warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Boom extension driving with rigged boom extension axle loads at 12 m (39 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22 at 18 m (59 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23 at 24 m (79 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 24

C

CHECKLIST bringing the boom system into operating condition – for luffing jib . . . . . . . . 8 - 9 bringing the boom system into operating condition – for the boom extension 7 - 9 bringing the boom system into operating condition – for the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5 bringing the boom system into operating condition – for the main boom . . . . 6 - 2 bringing the boom system into rigging mode – for luffing jib . . . . . . . . . . . . . 8 - 13 bringing the boom system into the rigging mode – for the boom extension . 7 - 10 bringing the boom system into the rigging mode – for the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6 bringing the boom system into the rigging mode – for the main boom . . . . . . 6 - 3 rigging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 unrigging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10 Crane control error messages on the display error messages - system control group . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 18 error messages via CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17 Crane control display submenu Operation – MWL function of operating instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11 opening the submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 77 overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 submenu Rigging – MWL function of operating instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20 overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 submenu Rigging – NW opening the submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 69

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D

Driving with rigged boom extension and rigged MWL . . . . . . . . . . . . . . . . . . . . . 7 - 19 Driving with rigged heavy load lattice extension and rigged MWL . . . . . . . . . . . 9 - 21 Driving with rigged luffing jib and rigged MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29 Driving with rigged main boom and rigged MWL . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29

F

Function of the Mega Wing Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4, 5 - 1

H

Hand-held control for the MWL connecting/removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 41 connection options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27 locking/unlocking the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 64 overview of button combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 32 raising and setting down the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 56 winding/unwinding the winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 65 Heavy load lattice extension driving with rigged heavy load lattice extension axle loads at 4 m (13 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24 at 7.5 m (25 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 25 turning loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15

I

Information about these operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

L

Luffing jib driving with a rigged luffing jib axle loads at 25 m (82 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33 at 31 m (102 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34 at 37 m (121 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34 at 43 m (141 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35 at 49 m (161 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35 at 55 m (180 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36 at 61 m (200 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36 at 67 m (220 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 37 at 73 m (240 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 37

M

Maintenance work on the Mega Wing Lift cleaning modules which must be protected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1 lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7 maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3

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M 12 maintenance plan every 12 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5 M 3 maintenance plan every three months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4 M 6 maintenance plan every six months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5 maintenance plan W weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4 maintenance plans D daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3 maintenance work guy ropes checking the condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15 checking the end fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13 checking the position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 9 lubricating the gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17 lubricating the joints on the holding frame . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12 winch gears changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19 checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 11 checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 11 lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15 winches lubricating the locking units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 18 Malfunctions during operation with the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3 when operating with the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6 Mega Wing Lift abbreviation used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 identification and slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

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Operating and display elements function of the additional elements in the luffing jib submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11 in the main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11 in the SLI submenu "Enter rigging mode" . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25 in the submenu Operation – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11 in the submenu Rigging – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20 on the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27 location of the additional elements on the crane control display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 position of the additional elements on the MWL hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8 on the SLI display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 Operation with boom extension and MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 driving with a rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19 driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20 driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20 further rigging work CHECKLIST – Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 CHECKLIST – Unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4 installing the deflection sheave with support roller . . . . . . . . . . . . . . . . . . . 7 - 5

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positioning the supporting roller on the foot section . . . . . . . . . . . . . . . . . . 7 - 6 to position the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 operation with braced boom system CHECKLIST – Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . . 7 - 9 CHECKLIST – Bringing into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10 setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 operation with MWL set down bringing into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15 CHECKLIST – Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . 7 - 13 Operation with heavy load lattice extension and MWL . . . . . . . . . . . . . . . . . . . . . . 9 - 1 driving with a rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21 driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21, 9 - 22 driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26 rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22 further rigging work extra information on positioning the hoist rope . . . . . . . . . . . . . . . . . . . . . . 9 - 4 operation with braced boom system CHECKLIST – Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . . 9 - 5 CHECKLIST – Bringing into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6 setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7 operation with MWL set down bringing into operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9 bringing into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 operation with the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . 9 - 11 setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 Operation with luffing jib and MWL driving with a rigged truck crane driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29 driving the rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 39 rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30 further rigging work CHECKLIST – Unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5 extra information on positioning the hoist rope . . . . . . . . . . . . . . . . . . . . . . 8 - 8 installing the deflection sheave with support roller . . . . . . . . . . . . . . . . . . . 8 - 6 positioning the supporting roller on the foot section . . . . . . . . . . . . . . . . . . 8 - 7 operation with braced boom system bracing the boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 22 CHECKLIST - Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . 8 - 13 CHECKLIST – Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . . 8 - 9 derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19 telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20 operation with MWL set down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25 bringing into operating condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23 bringing into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25 setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24 telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25 rigging mode – MWL is raised and not braced . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27 Operation with the main boom and the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1 driving with a rigged truck crane axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31 driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29 driving the rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 32

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rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 30 further rigging work CHECKLIST – Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 CHECKLIST – Unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 installing/removing the three-part holding rod . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 reeving the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6 operation with braced boom system brace the boom system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17 CHECKLIST – Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . . 6 - 9 CHECKLIST – Bringing into rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10 folding the gantry masts out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15 locking/unlocking the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19 opening the submenu Operation – MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13 setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11 telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14 operation with MWL set down bringing into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23 CHECKLIST – Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . 6 - 21 derricking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23 main boom operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23, 7 - 15 setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22, 7 - 14 telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23, 7 - 15 operation with unbraced boom system and raised MWL bringing into the rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 27 CHECKLIST – Bringing into operating condition . . . . . . . . . . . . . . . . . . . . . 6 - 25 derricking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 26 main boom operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 26 setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25 telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 26

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Rigging the Mega Wing Lift CHECKLIST rigging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 unrigging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10 connection between the holding frame and the main boom . . . . . . . . . . . . . . 5 - 35 connection between the MWL and the main boom . . . . . . . . . . . . . . . . . . . . . 5 - 31 connection between the raising cylinder and the main boom . . . . . . . . . . . . . 5 - 45 connection between the winches and the holding frame . . . . . . . . . . . . . . . . . 5 - 51 electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39 fastening the guide ropes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 28 folding in the gantry masts – from the crane cab . . . . . . . . . . . . . . . . . . . . . . . 5 - 77 folding in the gantry masts – with the hand-held control . . . . . . . . . . . . . . . . . 5 - 58 hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36 identification of the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 installing/removing the lateral head sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22 installing/removing the rests for the rear pendant links . . . . . . . . . . . . . . . . . . 5 - 17 locking/unlocking the winch – with the hand-held control . . . . . . . . . . . . . . . . 5 - 64 lowering the MWL onto the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 33 moving the deflection sleeves into the position Operation/Transport . . . . . . 5 - 52 moving the rope grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20 positioning/removing the guy ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 60 positioning/removing the hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 55

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Index

positions of the turnbuckles for the rear pendant links . . . . . . . . . . . . . . . . . . 5 - 50 preparing the truck crane for unrigging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 raising and setting down the MWL – from the crane cab . . . . . . . . . . . . . . . . . 5 - 70 raising and setting down the MWL – with the hand-held control . . . . . . . . . . 5 - 56 raising the MWL onto the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 34 securing/releasing the lateral head sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 66 slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 slinging the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27 transporting the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 68 using the rigging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26 winding/unwinding – with the hand-held control . . . . . . . . . . . . . . . . . . . . . . . 5 - 65 winding/unwinding the winches – from the crane cab . . . . . . . . . . . . . . . . . . . 5 - 75

Safety instructions, basic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Scope of delivery of the Mega Wing Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Slinging points on MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

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Transportation of the Mega Wing Lift transport dimensions and weights add-on parts – lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 add-on parts – truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Mega Wing Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 transport position of the MWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 68 turning loads with the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15

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