Manitowoc Grove Crane GMK4080-2 lattice extension Operating Manual

Operating instructions for lattice extension

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Wichtiger Hinweis Jegliche Arten der Vervielfältigung, sowie Auszüge aus diesem Dokument, auch in elektronischer Form, unterliegen nicht dem Änderungsdienst der Manitowoc Crane Group Germany GmbH.

© Copyright reserved by

Industriegelände West D-26389 Wilhelmshaven, Germany Tel: [+49] (0)44 21 294-0 Fax: +[49] (0) 44 21 294-301 Weitergabe und Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten zum Schadensersatz. Alle Rechte für den Fall der Patenteintragung und Gebrauchsmustereintragung vorbehalten. Sprache der Urfassung dieses Dokumentes - deutsch.

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Operating instructions for lattice extension GMK4080-2

19.06.2019

Manitowoc Crane Group Germany GmbH

These operating instructions contain the following sections:

1 About these operating instructions 2 Basic safety instructions 3 Operating elements 4 Rigging work on the main boom 5 Swing-away lattice 6 Boom extension 7 Heavy load lattice extension, 2.0 m (6.6 ft) 8 Heavy load lattice extension 1.8 m (5.9 ft) 9 Auxiliary single-sheave boom top 10 Turning loads over 11 Driving with a rigged crane

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12 Index

Operating instructions for lattice extension GMK4080-2

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Blank page

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Operating instructions for lattice extension GMK4080-2

1 About these operating instructions

1.1

Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

1

1.2

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

3

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Operating instructions for lattice extension GMK4080-2

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2 Basic safety instructions

2.1

Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1

2.2

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

2

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Operating instructions for lattice extension GMK4080-2

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Operating instructions for lattice extension GMK4080-2

3 3

Operating elements

3.1

On the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

2

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connection section 1/main boom, rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connection section 2/main boom, rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connection section 1/main boom, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connection section 1/section 2, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connection section 2/main boom, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connection section 1/section 2, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Section 2 control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

2 3 3 4 4 5 5 6

3.2

In the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7 On the CCS control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 On the CCS control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 At the right-hand control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10

3.3

On the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11

3.3.1

Connecting hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12

3.4

Other operating elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

3.4.1

Rigging hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

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3.2.1 3.2.2 3.2.3 3.2.4

Operating instructions for lattice extension GMK4080-2

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4 Rigging work on the main boom

4.1

Hose drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

1

4.1.1 4.1.2

Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

1 2

4.2

Rigging work on the hose drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

3

4.2.1 4.2.2 4.2.3 4.2.4

Fitting/removing the hose drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Checking the locking device on the hose drum . . . . . . . . . . . . . . . . . . . . . . . . . 4 Positions of the hydraulic connections during operation . . . . . . . . . . . . . . . . . . 4 Positions of the hydraulic hoses when rigging . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

3 5 6 8

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Operating instructions for lattice extension GMK4080-2

5 5

Swing-away lattice

5.1

Notes on this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1

5.2

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

2

5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7 Transport condition – removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8 Transport condition – folded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11

5.3

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

5.3.10

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 CHECKLIST: Installing the swing-away lattice – in operating position . . . . . . . 5 - 17 CHECKLIST: Installing the swing-away lattice – in transport position . . . . . . . . 5 - 21 CHECKLIST: Removing the swing-away lattice – from operating position . . . . 5 - 25 CHECKLIST: Removing the swing-away lattice – from transport position . . . . 5 - 31 CHECKLIST: Rigging the swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft) – in the operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35 CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – in the operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39 CHECKLIST: Rigging the swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft) – in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 45 CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 51 CHECKLIST: Further rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 57

5.4

Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 59

5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9

Notes on the position of the telescoping cylinder . . . . . . . . . . . . . . . . . . . . . . . . 5 - 59 Secure the swing-away lattice with guide rope . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 60 Establish/disconnect the connection section 2–main boom, front . . . . . . . . . . . . . . 5 - 61 Section 1/main boom, front – establish/disconnect the connection. . . . . . . . . . 5 - 63 Section 1/section 2, front – establish/disconnect the connection . . . . . . . . . . . . 5 - 64 Section 2/main boom, rear – establish/disconnect the connection . . . . . . . . . . 5 - 65 Section 1/main boom, rear – establish/disconnect the connection . . . . . . . . . . 5 - 66 Establishing/disconnecting the slewing connection . . . . . . . . . . . . . . . . . . . . . . 5 - 67 Establishing/disconnecting the connection between the main boom/ section 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 69 Relieving the strain on the connecting points . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 70 Section 1/section 2 – Establish/disconnect the left-hand connection . . . . . . . . . 5 - 73 Section 1/section 2 – Establish/disconnect the right-hand connection . . . . . . . 5 - 75 Swinging the swing-away lattice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 77 Swinging section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 79 Establishing/disconnecting the hydraulic connection – when rigging . . . . . . . . 5 - 80 Establishing/disconnecting the hydraulic connection – when installing . . . . . . 5 - 82

5.3.7 5.3.8

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5.3.9

5.4.10 5.4.11 5.4.12 5.4.13 5.4.14 5.4.15 5.4.16

Operating instructions for lattice extension GMK4080-2

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5.4.17 5.4.18 5.4.19 5.4.20 5.4.21 5.4.22 5.4.23 5.4.24 5.4.25 5.4.26 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 5.5.7

Establishing/disconnecting electrical connections. . . . . . . . . . . . . . . . . . . . . . .

Fold the deflection sheave in/out on section 2 . . . . . . . . . . . . . . . . . . . . . . . . . .

Attaching/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing/removing the anemometer and air traffic control light . . . . . . . . . .

Derricking the swing-away lattice for rigging work – hand-held control . . . . .

Installing/removing the camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking the swing-away lattice – Section 2 control unit . . . . . . . . . . . . . . . .

Setting the angle – with an auxiliary crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the angle – without an auxiliary crane . . . . . . . . . . . . . . . . . . . . . . . . . .

5 - 84 5 - 89 5 - 91 5 - 94 5 - 96 5 - 98 5 - 99 5 - 101 5 - 102 5 - 103

Operation with swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 109 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telescoping with rigged swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking the swing-away lattice in operation . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure if permissible wind speed is exceeded . . . . . . . . . . . . . . . . . . . . . .

Information about the main boom operation when the swing-away lattice is folded/rigged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 - 109 5 - 110 5 - 111 5 - 111 5 - 113 5 - 114 5 - 115

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 117

5.6.1 5.6.2 5.6.3 5.6.4 5.6.5

Maintenance plan W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 117 Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 117 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 117 Maintenance plan M 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 118 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 118

5.7

Finding and eliminating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 123

5.7.1

Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 123

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6 6

Boom extension

6.1

Notes on this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

1

6.2

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

3

6.2.1 6.2.2 6.2.3 6.2.4 6.2.5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

3 4 5 6 6

6.3

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

7

6.3.1 6.3.2 6.3.3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7 CHECKLIST: Installing the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8 CHECKLIST: Removing the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13

6.4

Description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19

6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6

6.4.8

Section 3 – Folding out/folding in the deflection sheave . . . . . . . . . . . . . . . . . . 6 - 19 Section 3/main boom – Establish/disconnect the connection. . . . . . . . . . . . . . . 6 - 20 Section 3/main boom – Establish/disconnect the electrical connections. . . . . . 6 - 22 Section 3/main boom – Establish/disconnect the hydraulic connection . . . . . . 6 - 24 Section 3/swing-away lattice – Establish/disconnect the connection. . . . . . . . . 6 - 25 Section 3/swing-away lattice – Establish/disconnect the electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 27 Section 3/swing-away lattice – Establish/disconnect the hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29 Section 3 – Fitting/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 30

6.5

Operation with boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31

6.5.1 6.5.2 6.5.3 6.5.4

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31 Derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 32 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . . . . . 6 - 33 Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 33

6.6

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 35

6.6.1 6.6.2 6.6.3

Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 35 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 35 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 36

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7 7

Heavy load lattice extension, 2.0 m (6.6 ft)

7.1

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

1

7.1.1 7.1.2 7.1.3 7.1.4 7.1.5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

1 2 3 4 5

7.2

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

7

7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.3

Description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25

7.3.1

7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.3.11 7.3.12

Section 5/main boom– Establish/separate the connection in the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 Section 5/main boom – Establish/separate the connection in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26 Bringing section 5 from the transport position into the working position. . . . . 7 - 28 Bringing section 5 from the working position into the transport position. . . . . 7 - 30 Folding the rope attachment point in/out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 32 Section 5 – Setting the angle – with the hoist rope . . . . . . . . . . . . . . . . . . . . . . . 7 - 33 Section 5 – Setting the angle – with a chain hoist . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35 Section 5 –Fitting/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37 Possible reeving methods on the heavy load lattice extension . . . . . . . . . . . . . 7 - 38 Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39 Installing / removing the anemometer and air traffic control light . . . . . . . . . . 7 - 41 Installing/removing the camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 42

7.4

Operating the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45

7.4.1 7.4.2 7.4.3 7.4.4

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45 Derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 47 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . . . . . 7 - 48 Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 48

7.5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49

7.3.2

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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) installation into the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) Installation into the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) removal from the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) removal from the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) rigging into the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) rigging into the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21

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Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50

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8 8

Heavy load lattice extension 1.8 m (5.9 ft)

8.1

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

1

8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6

Possible operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

1 2 2 3 5 6

8.2

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

9

8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.3

Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27

8.3.1

8.3.3 8.3.4 8.3.5 8.3.6 8.3.7 8.3.8 8.3.9 8.3.10 8.3.11 8.3.12 8.3.13 8.3.14 8.3.15

Section 6/main boom – Establish/separate the connection in the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27 Section 6/main boom– Establish/separate the connection in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28 Bringing section 6 from the transport position into the working position. . . . . 8 - 30 Bringing section 6 from the working position into the transport position. . . . . 8 - 32 Folding the rope attachment point in/out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35 Section 6 – Setting the angle - with the hoist rope . . . . . . . . . . . . . . . . . . . . . . . 8 - 36 Section 6 – Setting the angle - with a chain hoist . . . . . . . . . . . . . . . . . . . . . . . . 8 - 38 Section 6 – Fitting/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40 Possible reeving methods on the heavy load lattice extension . . . . . . . . . . . . . 8 - 41 Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 43 Installing / removing the anemometer and air traffic control light . . . . . . . . . . 8 - 45 Installing/removing the camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 46 Installing/removing the air traffic control light. . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 48 Installing/removing the shackle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 50 Folding in/folding out the shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 52

8.4

Heavy load lattice extension – Operation with hoist rope . . . . . . . . . . . . . . . . . . 8 - 53

8.4.1

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53

8.3.2

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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) installation into the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) installation into the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) removal from the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) removal from the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) rigging into the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) rigging into the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23

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8.4.2 8.4.3 8.4.4

Derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55 Procedure if permissible wind speeds are exceeded. . . . . . . . . . . . . . . . . . . . . 8 - 56 Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 56

8.5

Heavy load lattice extension – Operation with a shackle . . . . . . . . . . . . . . . . . . 8 - 57

8.5.1 8.5.2 8.5.3 8.5.4

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure if permissible wind speeds are exceeded. . . . . . . . . . . . . . . . . . . . .

8 - 57 8 - 59 8 - 61 8 - 62

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63

8.6.1 8.6.2 8.6.3 8.6.4

Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63 Maintenance plan M 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 64

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9 9

#+Auxiliary single-sheave boom top

9.1

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

1

9.1.1 9.1.2 9.1.3

Identification and slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

1 2 2

9.2

Description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

5

Moving the auxiliary single-sheave boom top into operating position . . . . . . . 9 - 5 Moving the auxiliary single-sheave boom top into the transport position . . . . 9 - 7 Installing/removing a folded auxiliary single-sheave boom top . . . . . . . . . . . . 9 - 9 Attaching/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12 Installing/removing the anemometer and air traffic control light . . . . . . . . . . . 9 - 14 Installing/removing the camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14

9.3

Operation with the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . 9 - 15

9.3.1 9.3.2 9.3.3

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . . . . . 9 - 17 Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17

9.4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19

9.4.1 9.4.2 9.4.3

Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20

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9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7

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Operating instructions for lattice extension GMK4080-2

10 Turning loads over

10.1

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

2

10.2

Turning a load over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

3

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10

Operating instructions for lattice extension GMK4080-2

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Operating instructions for lattice extension GMK4080-2

11 11

Driving with a rigged crane

11.1

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

1

11.2

Driving path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

2

11.3

Permissible rigging modes and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -

3

Swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4 Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8 Heavy load lattice extension 2.0 m (6.6 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10 Heavy load lattice extension 1.8 m (5.9 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12 Auxiliary single-sheave boom top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 14

11.4

Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15

11.5

While driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15

11.6

After driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15

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11.3.1 11.3.2 11.3.3 11.3.4 11.3.5

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Operating instructions for lattice extension GMK4080-2

12 Index

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Operating instructions for lattice extension GMK4080-2

About these operating instructions 1.1 Validity

1

About these operating instructions

1.1

Validity

Validity of these operating instructions

Manitowoc Crane Group Germany GmbH.

This operating manual applies only to lattice extensions supplied by

For the operation of the truck crane with a lattice extension described in these operating instructions, also follow all instructions in the accompanying Operating instructions GMK4080-2 for which the lattice extensions have been supplied by the factory.

Prerequisites for assembly and operation

The lattice extensions described in this operating manual may only be operated together with a GROVE truck crane GMK4080-2 whose serial number is identical with the serial number marked on the lattice extensions.

References to other operating manuals

Cross references to other operating or maintenance manuals are shown like Operating instructions GMK4080-2. this:

à

19.06.2019

The subject that is referenced can be found in the index or table of contents of the document to which reference is made.

Operating instructions for lattice extension GMK4080-2

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1-1

About these operating instructions 1.1 Validity

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Blank page

1-2

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Operating instructions for lattice extension GMK4080-2

About these operating instructions 1.2 Terms used

1.2

Terms used An overview of the lattice extensions described in this operating manual is provided below.

1

Section 1 for the swing-away lattice

2.1

Section 2 for the derricking swing-away lattice

2.2

Section 2 for the inclinable swing-away lattice

3

Section 4 for the boom extension

4

Rigging aid for the inclinable swing-away lattice1)

5

Section 5, heavy load lattice extension

6

Section 6, heavy load lattice extension

7

Auxiliary single-sheave boom top

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1) Additional equipment

Operating instructions for lattice extension GMK4080-2

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1-3

About these operating instructions 1.2 Terms used

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1-4

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Operating instructions for lattice extension GMK4080-2

Basic safety instructions 2.1 Other applicable documents

2

Basic safety instructions In principle, all the basic safety instructions from the Operating instructions GMK4080-2 are applicable.

Observe also all safety instructions and warnings on the truck crane!

H 2.1

Information regarding the warnings and symbols used; à Operating instructions GMK4080-2.

Other applicable documents In addition to the information in this operating manual, all the instructions in the following sections of the supplied Operating instructions GMK4080-2 are also applicable: – Intended use – Improper use – Organisational measures

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– Qualifications of personnel on the GMK4080-2

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2-1

Basic safety instructions 2.2 Safety instructions for working with a lattice extension

2.2

Safety instructions for working with a lattice extension This chapter only contains additional safety instructions for safe use of the lattice extensions described in these operating instructions.

Working at heights

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

The lattice extensions are provided with brackets for positioning a ladder.

Place the ladder between the brackets so it cannot slip off.

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

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

Slinging

Attach slings to the sections only at the designated slinging points. If no slinging points are provided, refer to the centre of gravity data

.

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

Locks

Always secure the pins at the connection points and also at the holders using the appropriate locks. This prevents unsecured pins coming loose, falling out and causing injuries.

Rigging mode

For crane operation with the lattice extension folded away, observe the rigging mode. This will prevent damage to the main boom or lattice extension, and you will prevent the lattice extension falling during crane operation.

For on-road driving with the lattice extension, observe the rigging mode.

This prevents the permissible vehicle width or height being exceeded.

Lifting loads simultaneously with two cranes is particularly dangerous.

Carry out this type of work with special care.

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Operating elements

3

Operating elements

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This section describes all the lattice extension operating elements that are not described or merely referenced in the supplied Operating instructions GMK4080-2.

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3-1

Operating elements 3.1 On the lattice extension

3.1

On the lattice extension

3.1.1

Overview

Console rear

1.1

Connection section 1–main boom, rear

2

Console centre

2.1

Connection section 1–main boom, front

2.2

Connection section 1–section 2, front

3

Console front

3.1

Connection section 2–main boom, front

3.2

Connection section 2–main boom, rear

4

Connection section 1–section 2, rear

à p. 3 - 3 à p. 3 - 4 à p. 3 - 4 à p. 3 - 5 à p. 3 - 3 à p. 3 - 5

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3-2

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Operating instructions for lattice extension GMK4080-2

Operating elements 3.1 On the lattice extension

3.1.2

Connection section 1/main boom, rear (A) – Establishing the connection The pin (1) is inserted and secured in the connecting point.

(B) – Disconnecting the connection The pin (1) is removed from the connecting point. The pin is inserted and secured in the connecting point.

à p. 5 - 66

3.1.3

Connection section 2/main boom, rear (A) – Establishing the connection The pin (1) is inserted and secured in the connecting point.

(B) – Disconnecting the connection The pin (1) is removed from the connecting point. The pin is inserted and secured in the connecting point.

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à p. 5 - 65

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3-3

Operating elements 3.1 On the lattice extension

3.1.4

Connection section 1/main boom, front (A) – Establishing the connection The pin (1) is inserted and secured in the connecting point.

(B) – Disconnecting the connection The pin (1) is removed from the connecting point. The pin is inserted and secured in the connecting point.

à p. 5 - 63

3.1.5

Connection section 1/section 2, front (A) – Establishing the connection The pin (1) is inserted and secured in the connecting point.

(B) – Disconnecting the connection The pin (1) is removed from the connecting point. The pin is inserted and secured in the connecting point.

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à p. 5 - 64

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Operating instructions for lattice extension GMK4080-2

Operating elements 3.1 On the lattice extension

3.1.6

Connection section 2/main boom, front (A) – Establishing the connection The pin (1) is inserted and secured in the connecting point.

(B) – Disconnecting the connection The pin (1) is removed from the connecting point. The pin is inserted and secured in the connecting point.

à p. 5 - 61

3.1.7

Connection section 1/section 2, rear The connection is established with the pins (1).

The pins (1) are inserted into connecting points (2) or in the holders (3), depending on whether section 1 is folded in or folded in front of section 2.

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à p. 5 - 73 à p. 5 - 75

Operating instructions for lattice extension GMK4080-2

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3-5

Operating elements 3.1 On the lattice extension

3.1.8

Section 2 control unit

1 Raise swing-away lattice extension 2 Lower swing-away lattice extension The movement is carried out as long as the button is pushed down or until a switch-off point is reached.

1 Raise swing-away lattice extension 2 Lower swing-away lattice extension

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The movement is carried out as long as the button is pushed down or until a switch-off point is reached.

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Operating instructions for lattice extension GMK4080-2

Operating elements 3.2 In the crane cab

3.2

In the crane cab

3.2.1

Overview

1 On the CCS control unit 2 On the CCS control unit

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3 At the right-hand control console

à p. 3 - 9 à p. 3 - 8 à p. 3 - 10

Operating instructions for lattice extension GMK4080-2

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3-7

Operating elements 3.2 In the crane cab

3.2.2

On the CCS control unit Lattice extension derricking gear display – Green:

Derricking gear of the lattice extension on

– Red:

Derricking gear of the lattice extension off

Power unit speeds menu – input speed – lattice extension derricking gear The value (xx) indicates what percentage of the maximum speed is Operating instructions GMK4080-2. permitted. To change the value;

à

Operating hours menu – lattice extension derricking gear operating hours The value indicates the operating hours for the derricking gear of the lattice Operating instructions GMK4080-2. extension. Further information;

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à

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Operating instructions for lattice extension GMK4080-2

Operating elements 3.2 In the crane cab

3.2.3

On the CCS control unit

Enter rigging mode/telescope status menu

Only for the slewing range type Standard.

Entering the boom system In input mode – select and confirm the boom system 1 Main boom 2 Lattice extension/boom extension 3 Heavy load lattice extension – operation with hoist rope 4 Heavy load lattice extension – operation with a shackle

Entering the lattice extension – length before the angle In input mode – select and confirm length.

Entering the lattice extension – length after the angle Entering the heavy load lattice extension – length In input mode – select and confirm length.

Entering the lattice extension – angle Only for manually inclinable lattice extensions

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In input mode – select and confirm the angle.

Operating instructions for lattice extension GMK4080-2

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3-9

Operating elements 3.2 In the crane cab

3.2.4

At the right-hand control console Lattice extension derricking gear on/off There is a lamp in the button.

– Press once:

– Bright lamp – derricking gear of lattice extension on – Dim lamp – derricking gear of lattice extension off

Control lever configuration – Raise – Lift the lattice extension

– To the right

– Lower – Lower the lattice extension

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– To the left:

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Operating instructions for lattice extension GMK4080-2

Operating elements 3.3 On the hand-held control

3.3

On the hand-held control This section is only valid for the derricking swing-away lattice. The operations are not monitored by the RCL. The button (1) is active only when the swing-away lattice is connected electrically.

For operation, you must pre-select a function and then press the required combination of buttons.

Pre-selecting – Lattice extension derricking gear:

Press button (1) once – the lamp in the button lights up

The pre-selection remains in force until superseded by another pre-selection.

Function buttons There are two button combinations; buttons that are engaged are shown in black: – Pre-selected function on Press the required button combination.

– Pre-selected function off Release one or both the buttons.

Press a non-assigned button combination – pre-selection off.

To raise the lattice extension: Press button combination shown

To lower the lattice extension: Press button combination shown

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s Operating instructions for lattice extension GMK4080-2

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3 - 11

Operating elements 3.3 On the hand-held control

3.3.1

– Faster movement:

Increase pressure on button

– Slower movement:

Decrease pressure on button

Connecting hand-held control With the hand-held control Derricking the swing-away lattice is enabled at the sockets (1) and (2).

Connection to the socket (2) is not suitable for rigging as you cannot see the folded swingaway lattice from this point.

The socket (2) is intended for emergency operation.

• Connect the hand-held control to the socket (1).

à Operating instructions GMK4080-2.

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Connecting the hand-held control

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Operating instructions for lattice extension GMK4080-2

Operating elements 3.4 Other operating elements

3.4

Other operating elements

3.4.1

Rigging hook You can also actuate various control elements on the swing-away lattice using the rigging hook (1).

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The rigging hook is fastened in the clamps (2).

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3 - 13

Operating elements 3.4 Other operating elements

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3 - 14

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Operating instructions for lattice extension GMK4080-2

Rigging work on the main boom 4.1 Hose drum

4

Rigging work on the main boom

4.1

Hose drum The hydraulic supply to the derricking lattice extension is provided via a hose drum on the side of the main boom.

4.1.1

Slinging points • Attach the hose drum (1) as shown using

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a strap sling of sufficient load bearing capacity.

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4-1

Rigging work on the main boom 4.1 Hose drum

4.1.2

Length x width x height in m (ft)

Weight in kg (lbs)

1.20 x 1.20 x 0.4 (3.9 X 3.9 x 1.3)

150 (331)

Risk of damaging the hose drum Always secure the hose drum by tying it down with suitable belts when it is transported on a separate vehicle. This prevents the hose drum tipping over and becoming damaged during transport.

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S

Transport dimensions and weights

4-2

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Operating instructions for lattice extension GMK4080-2

Rigging work on the main boom 4.2 Rigging work on the hose drum

4.2

Rigging work on the hose drum

4.2.1

Fitting/removing the hose drum

Installing

For crane operation, if the hose drum is not already installed you must install it.

• Attach lifting gear to the hose drum (1);

à Slinging points, p. 4 - 1.

• (A) – Remove the pin (2) from the holder.

• (B) – Hoist the hose drum (1) into the holder (4).

• Secure the hose drum (1) in the clamp (3) using the pin (2).

• Secure the pin.

• Connect the hoses (2) to the connections (1) (match the markings).

• Release the locking device (4); à p. 4 - 5.

• Move the hoses (3) to the correct position for the desired operation;

à p. 4 - 6.

• Check the connections for leaks.

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4-3

Rigging work on the main boom 4.2 Rigging work on the hose drum

Removing

Depending on the driving mode it may be necessary to remove the hose drum before driving on the road; Operating instructions GMK4080-2.

à

• Insert the locking device (3); à p. 4 - 5.

• Remove the hoses (4) from the main boom and place them on the hose drum.

• Detach the hoses (2) from the connections (1).

• Use the caps to close the hoses (2) and the connections (1).

• Attach lifting gear to the hose drum (1);

à Slinging points, p. 4 - 1.

• (A) – Remove the pin (2) from the holder (3).

• Hoist the hose drum (1) out of the clamp (4).

• (B) – Insert the pin (2) into the clamp (5).

• Secure the pin.

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• Stow the hose drum (1) safely for transport.

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Operating instructions for lattice extension GMK4080-2

Rigging work on the main boom 4.2 Rigging work on the hose drum

4.2.2

Checking the locking device on the hose drum The locking device must be released before operating the crane with the swing-away lattice.

The locking device must be engaged before removal of the hose drum.

S G

Risk of damage to the hoses Always check that the locking device is released before beginning operation with the swing-away lattice.

In this way you can prevent the hoses being torn off when telescoping.

Risk of accidents from uncontrolled rotation of the hose drum The locking device must always be engaged before the hose drum is removed. Otherwise the hose drum will rotate uncontrollably against the clamp and could injure you.

There are holes (1) distributed around the inner face of the hose drum.

A – Releasing the locking device

• Rotate the spring latch (2) so that it is not engaged in a hole (1).

B – Engaging the locking device

• Rotate the hose drums so that the spring latch (2) is aligned with a hole (1).

• Rotate the spring latch (2) so that it engages

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in the hole (1). The hose drum is now secured against rotation.

Operating instructions for lattice extension GMK4080-2

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4-5

Rigging work on the main boom 4.2 Rigging work on the hose drum

4.2.3

G

Positions of the hydraulic connections during operation Risk of accidents from hoses springing back If you detach the hoses after the locking device has been released, do not under any circumstances let go of the hoses before they has been re-secured. Otherwise the hoses will retract uncontrollably and can injure people or damage parts of the truck crane.

Working with the lattice extension

G

Risk of crushing due to movement of swing-away lattice Start the subsequent work only if the swing-away lattice is locked in front of the main boom head or it is secured against swinging.

This will prevent the swing-away lattice from swinging inadvertently to the side of the main boom and possibly crushing you.

The locking device on the hose drum is released;

à p. 4 - 5.

The connections (6) are hung in the holder (5).

• Release the linchpins (1) and fold down the guide sheaves (2).

• Pull the hoses (4) forwards and hang the connections (6) on the holder (3).

• Push the hoses under the guide sheaves (7).

• Fold up the guide sheaves (2) and secure

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them with the linchpins (5).

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Operating instructions for lattice extension GMK4080-2

Rigging work on the main boom 4.2 Rigging work on the hose drum

Main boom operation

G S

The locking device on the hose drum is released;

à p. 4 - 5.

Risk of crushing due to swinging lattice extension Start the subsequent work only if the swing-away lattice is locked in front of the main boom head or it is secured against swinging.

This will prevent the swing-away lattice from swinging inadvertently to the side of the main boom and possibly crushing you.

Risk of damage to the hydraulic hoses Always remove the hoses from the holder and from the guide sheaves before you swing the swing-away lattice to the side of the main boom.

In this way, you prevent the hoses from kinking and being damaged when swinging the lattice.

• Release the linchpins (1) and fold down the guide sheaves (2).

• Remove the connections (4) from holder (5) and insert them in holder (3).

• Fold up the guide sheaves (2) and secure

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them with the linchpins (1).

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4-7

Rigging work on the main boom 4.2 Rigging work on the hose drum

4.2.4

Positions of the hydraulic hoses when rigging

When unrigging

G S

Risk of crushing due to swinging lattice extension Start the subsequent work only if the lattice extension is locked in front of the main boom head or it is secured against swinging around.

This will prevent the lattice extension from swinging inadvertently to the side of the main boom and possibly crushing you.

Risk of damage to the hydraulic hoses Always remove the hydraulic hoses from the holder and from the guide sheaves before you swing the lattice extension to the side of the main boom.

In this way, you prevent the hydraulic hoses from kinking and being damaged when folding the lattice extension.

Before folding

• Remove the linchpins (1) and fold the guide sheaves (2) down.

The hoses (4) will drop down.

• Remove the connections (6) from holder (3) and place the hoses in holder (5).

• Fold up the guide sheaves (2) and secure

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them with the linchpins (1).

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Operating instructions for lattice extension GMK4080-2

Rigging work on the main boom 4.2 Rigging work on the hose drum

When rigging

G

Risk of crushing due to swinging lattice extension Start the subsequent work only if the lattice extension is locked in front of the main boom head or it is secured against swinging around.

This will prevent the lattice extension from swinging inadvertently to the side of the main boom and possibly crushing you.

After folding After swinging, the connections (5) will hang under the guide sheaves (2).

• Remove the linchpins (1) and fold the guide sheaves (2) down.

• Pull the hydraulic hoses (4) forwards and hang the connections (5) on the holder (3).

• Place the hydraulic hoses in guide sheave (6).

• Fold up the guide sheave (2) and secure it with the linchpin (1).

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• Do the same for the other guide sheaves (2).

Operating instructions for lattice extension GMK4080-2

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4-9

Rigging work on the main boom 4.2 Rigging work on the hose drum

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.1 Notes on this chapter

5

Swing-away lattice

5.1

Notes on this chapter Where the lifting capacity table uses the term swing-away lattice extension, in this chapter the term swing-away lattice is used.

This chapter applies to the: – Derricking swing-away lattice The inclination of the derricking swingaway lattice is adjusted with the hydraulic cylinder (1).

Rigging work that applies only to this swingaway lattice is indicated in the checklists with the symbol (1.1).

– Inclinable swing-away lattice The inclination of the inclinable swing-away lattice is adjusted with the angle piece (2).

Rigging work that applies only to this swingaway lattice is indicated in the checklists with the symbol (2.1).

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Text that applies only to one of the swingaway lattices is explicitly indicated.

Operating instructions for lattice extension GMK4080-2

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5-1

Swing-away lattice 5.2 Operations planning

5.2

Operations planning

5.2.1

Assembly

S

Risk of overturning in other combinations Assemble the swing-away lattice only in the combinations listed as permissible in the lifting capacity table. Other combinations are not monitored by the RCL.

Permissible combinations

Designation

Z + Y 1)

Sections used

A

Swing-away lattice A

1.2 + 7.5 m (3.9 + 24.6 ft)

2

B

Swing-away lattice B

1.2 + 13.8 m (3.9 + 45.3 ft)

2+1

Designation in the lifting capacity table: Z = length before setting the angle Y = length after setting the angle 19.06.2019

1)

Combination

5-2

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.2 Operations planning

5.2.2

G

Identification Risk of accidents when using an incorrect swing-away lattice Install only the swing-away lattice that belongs to the truck crane.

Other swing-away lattices must not be installed.

Section 1 (1) is marked with the serial number (3).

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Section 2 (2) is marked with the serial number (3) on the inclinable part and on the fixed part.

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5-3

Swing-away lattice 5.2 Operations planning

5.2.3

Slinging points Transport dimensions and weights; p. 4 - 2.

à Transport dimensions and weights,

On section 1

G

Risk of accidents if used improperly Attach slings to the swing-away lattice only at the designated slinging points. Use only lifting gear and joining elements of sufficient load bearing capacity.

The slinging points (1) are marked with stickers (2).

The sticker (3) gives the weight and the necessary lifting gear.

A guide rope (4) is fastened behind the head of section 1.

Section 2 and combinations

à

.

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G

Risk of accidents due to falling parts Always observe the centre of gravity shown in following table when slinging and use suitable slinging material with sufficient load bearing capacity; Transport dimensions and weights, p. 4 - 2 In this way, you prevent the attached sections from slipping out, falling and causing potentially fatal injury during installation or removal.

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.2 Operations planning

A B C

1)

Section and section combination

Distance to centre of gravity in m (in) 1)

2 + 1 (folded out) 2 + 1 (folded back) 2

5,300 mm (208.7 in) 3,850 mm (151.6 in) 3,280 mm (129.1 in)

All distances are measured from the centre of the fork elements.

All distances are valid for both the derricking swing-away lattice and the inclinable swing-away lattice.

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Operating instructions for lattice extension GMK4080-2

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5-5

Swing-away lattice 5.2 Operations planning

• Fasten the lifting gear on the right and the

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left at the same distance A from the centre of gravity S.

5-6

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.2 Operations planning

5.2.4

Transport dimensions and weights

Section

Length x width x height in m (ft)

Weight in kg (lbs)

1

6.5 x 0.50 x 0.55 (21.30 x 1.65 x 1.80)

270 (595)

2 2 + 1 (folded out)

8.9 x 0.55 x 1.35 (29.2 x 1.80 x 4.40)

720 (1,590)

15.40 x 1.10 x 1.35 (50.50 x 3.60 x 4.40)

990 (2,185)

8.9 x 1.10 x 1.35 (29.2 x 3.60 x 4.40)

990 (2,185)

2 + 1 (folded back)

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The following values apply for both the derricking and inclinable swingaway lattice.

Operating instructions for lattice extension GMK4080-2

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5-7

Swing-away lattice 5.2 Operations planning

5.2.5

Risk of damage to the lattice extension Always secure the lattice extension by tying it down with suitable belts when it is transported on a separate vehicle. This prevents the lattice extension from tipping over and becoming damaged during transport.

Risk of injury Before transporting, make sure that all pins are secured in their holders with retaining pins. Secure any pins that are not secure.

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

Risk of injury Before transport, ensure that all cables and hoses are securely fastened in their holders and cannot come loose during driving. Additionally fasten the cables and hoses if necessary.

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

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S G G

Transport condition – removed

5-8

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.2 Operations planning

On the swingaway lattice

Check that the lattice is secured in transport condition and secure it now if necessary.

– The connection section 1-section 2 rear right (1) is established; Section 1/section 2 – Establish/disconnect the right-hand connection, p. 5 - 75. All pins that are not required are secured in the holder (2).

– The swing-away lattice must be set down and secured on a suitable support (10).

– The connection section 1-section 2 front (6) is established; p. 5 - 64.

à

à

– The pins (9) are secured in the holder;

à p. 5 - 67.

– The pins (8) are secured in the holders on both sides;

à p. 5 - 69.

– All electrical cables are closed with caps.

– The electrical connection (3) between section 1–section 2 is p. 5 - 84. disconnected;

à

Additionally for the inclinable swing-away lattice: – The swing-away lattice is in the 0° position (5); p. 5 - 103.

à

à p. 5 - 102,

Additionally for the derricking swing-away lattice:

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– The swing-away lattice is in the 0° position (6);

à p. 5 - 98.

– The hoses (7) are stored in the holder and the connections are closed p. 5 - 80. with caps;

à

Operating instructions for lattice extension GMK4080-2

s

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5-9

Swing-away lattice 5.2 Operations planning

On the main boom

• Check that the lattice is secured in transport condition and secure it now if necessary.

– On the console front, the pin (1) is inserted in the holder (2) and secured.

– On the derricking swing-away lattice, the connections hang in the holder (3); p. 5 - 80.

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à

5 - 10

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.2 Operations planning

5.2.6

S

Transport condition – folded Risk of damage to the lattice extension and the main boom Always put all equipment in the transport position for on-road driving before driving the truck crane with a folded swing-away lattice.

Only then is the swing-away lattice secured against slipping.

This prevents the partly fastened swing-away lattice from hitting the main boom or the individual components of the swing-away lattice from hitting each other and becoming damaged.

Section 1 only

• Check that the lattice is secured in transport condition and secure it now if necessary.

– The pins (1) from the connection section 1–section 2, rear are secured in the holder; p. 5 - 75, p. 5 - 73.

à

à

– The connection section 1-main boom, rear (2) is established;

à p. 5 - 66.

– On the derricking swing-away lattice, the connections hang in the holder (4); p. 5 - 80.

à

– The connection section 1-main boom, front (3) is established;

à p. 5 - 63.

– All electrical connections are closed with caps.

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5 - 11

Swing-away lattice 5.2 Operations planning

Section 2 only

• Check that the lattice is secured in transport condition and secure it now if necessary.

à p. 5 - 65.

– The connection section 2-main boom, front (2) is established; à p. 5 - 61.

– The connection section 2-main boom, rear (1) is established;

– On the derricking swing-away lattice, the connections hang in the holder (3) and are closed with caps. The hydraulic hoses (4) are fixed; p. 5 - 80.

à

– The pins (6) are secured in the holder;

à p. 5 - 69.

à p. 5 - 67.

– The deflection sheave (8) is folded in and secured; à p. 5 - 89.

– The pins (5) are secured in the holders on both sides;

– The electrical connection between section 2 – main boom (7) is disconnected and the cable has been wound onto the holder; p. 5 - 84.

à

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– All electrical connections are closed with caps.

5 - 12

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.2 Operations planning

Section 1 and section 2

• Check that the lattice is secured in transport condition and secure it now if necessary.

– The connection section 1-section 2 rear right (1) is established; Section 1/section 2 – Establish/disconnect the right-hand connection, p. 5 - 75. All pins that are not required are secured in the holder (2).

– The connection section 2-main boom, rear (3) is established; p. 5 - 65.

à

à

– The connection section 2–main boom, front (4) is established; p. 5 - 61.

à

– On the derricking swing-away lattice, the connections hang in the holder (5) and are closed with caps. The hydraulic hoses (6) are fixed; p. 5 - 80.

à

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5 - 13

Swing-away lattice 5.2 Operations planning

– The connection section 1–section 2, front (7) or the connection section 1– p. 5 - 63, p. 5 - 64. main boom, front (8) is established;

à

à

– The electrical connection between section 2 – main boom (9) is disconnected and the cable has been wound onto the holder; p. 5 - 84.

à

à p. 5 - 89.

– The pins (11) are secured in the holders on both sides; à p. 5 - 69.

– The pins (12) are secured in the holder; à p. 5 - 67.

– The deflection sheave (10) is folded in and secured;

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– All electrical connections are closed with caps.

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.3 Checklists for rigging work

5.3

Checklists for rigging work

5.3.1

Overview There are a number of different procedures.

– Installation and removal These procedures must be performed when the lattice extension is being transported separately. The installation and removal of the lattice extension is described.

– Rigging The rigging procedures must be performed when the lattice extension is being transported on the truck crane. The changeover between the transport position and the operating position is described.

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5 - 15

Swing-away lattice 5.3 Checklists for rigging work

The table shows which checklist is applicable to any required rigging work.

Required rigging work – Installing swing-away lattice

Swing-away lattice

– Removing the swingaway lattice

– Rigging the swing-away lattice

Checklist

– In operating position

CHECKLIST: Installing the swing-away lattice – in operating position, p. 5 - 17

– In transport position

CHECKLIST: Installing the swing-away lattice – in transport position, p. 5 - 21

– From operating position

CHECKLIST: Removing the swing-away lattice – from operating position, p. 5 - 25

– From transport position

CHECKLIST: Removing the swing-away lattice – from transport position, p. 5 - 31

– In operating position

CHECKLIST: Rigging the swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft) – in the operating position, p. 5 - 35 CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – in the operating position, p. 5 - 39

– In transport position

CHECKLIST: Rigging the swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft) – in the transport position, p. 5 - 45

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CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – in the transport position, p. 5 - 51

5 - 16

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.3 Checklists for rigging work

5.3.2

CHECKLIST: Installing the swing-away lattice – in operating position

H

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

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to Operating instructions GMK4080-2. the side or to the rear;

à

– The appropriate counterweight for operation of the crane must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– The main boom is lowered to the horizontal position; instructions GMK4080-2.

à Operating

– An auxiliary crane must be available.

2. If necessary, mount the hose drum;

à p. 4 - 3.

3. If necessary, check that the locking device has been released; p. 4 - 5.

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à

s Operating instructions for lattice extension GMK4080-2

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5 - 17

Swing-away lattice 5.3 Checklists for rigging work

4. If necessary, move the hoses into the position for working with the lattice extension; p. 4 - 6.

à

5. Check that the swing-away lattice is secured for transport;

à p. 4 - 2.

6. Folding out the deflection sheave: On section 2;

à p. 5 - 89

7. Sling lifting gear to the swing-away lattice sections required for combination A or B and fasten a guide rope.

à Assembly, p. 5 - 2, à Identification, p. 5 - 3, à Transport dimensions and weights, p. 5 - 7, à Slinging points, p. 5 - 4.

8. Lift the required section combination in front of the main boom.

9. Establish the connections on the right and left of the main boom head; p. 5 - 69.

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à

5 - 18

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Swing-away lattice 5.3 Checklists for rigging work

10. For a derricking swing-away lattice: Establish the hydraulic connection to the main boom;

à p. 5 - 82.

11. Establish the electrical connection to the main boom;

à p. 5 - 85.

12. For combination A – Position the hoist rope;

à p. 5 - 91.

13. For combinations B – Establish the electrical connection between section 1 and section 2; p. 5 - 87.

à

– Fasten a guide rope to section 1;

à p. 5 - 60.

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– Disconnect the connection section 1–section 2, front;

à p. 5 - 64.

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Swing-away lattice 5.3 Checklists for rigging work

– Swing section 1 in front of section 2;

à p. 5 - 79.

– Establish the connection on the left between section 1 and section 2; p. 5 - 73.

à

– Position the hoist rope;

à p. 5 - 91.

14. Remove the guide rope.

15. For an inclinable swing-away lattice: Set the angle position if necessary: – With auxiliary crane; p. 5 - 102 – Without auxiliary crane; p. 5 - 103

à

à

à p. 5 - 57.

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16. Perform all further rigging work;

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Swing-away lattice 5.3 Checklists for rigging work

5.3.3

CHECKLIST: Installing the swing-away lattice – in transport position

H

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

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear; Operating instructions GMK4080-2.

– The appropriate counterweight for operation of the crane must be rigged; Operating instructions GMK4080-2.

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

– The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

– An auxiliary crane must be available.

à

à

à

à

2. For a derricking swing-away lattice: – If necessary, mount the hose drum;

à p. 4 - 3.

– If necessary, check that the locking device has been released; p. 4 - 5.

à

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Swing-away lattice 5.3 Checklists for rigging work

3. Check that the swing-away lattice is secured for transport; condition – removed, p. 5 - 8.

à Transport

4. Sling the swing-away lattice to the auxiliary crane and fasten a guide rope;

à Slinging points, p. 5 - 4, à Secure the swing-away lattice with guide rope, p. 5 - 60.

5. Lift the swing-away lattice onto the main boom.

6. Establish the slewing connection;

G

à p. 5 - 67.

Risk of crushing due to swinging lattice extension Always secure the lattice extension against swinging using the auxiliary crane and the guide rope before you establish the hydraulic or electrical connection.

This will prevent the lattice extension from swinging inadvertently to the side of the main boom and possibly crushing you.

7. For a derricking swing-away lattice:

à p. 5 - 82.

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– Establish the hydraulic connection;

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Swing-away lattice 5.3 Checklists for rigging work

– Connect the hand-held control;

à p. 3 - 12.

8. Establish the electrical connection to the main boom;

à p. 5 - 85.

9. Swing the lattice extension onto the side of the main boom with a guide p. 5 - 77. rope;

à

10. For a derricking swing-away lattice: Lower the swing-away lattice until it rests on the console, rear; p. 5 - 98.

à

11. For combination A or B – Establish the connection between section 2–main boom, front; p. 5 - 61.

à

– Establish the connection between section 2–main boom, rear; p. 5 - 65.

à

12. For a derricking swing-away lattice:

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– Disconnect the hydraulic connection;

à p. 5 - 83.

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Swing-away lattice 5.3 Checklists for rigging work

– Detach the hand-held control;

à Operating instructions GMK4080-2.

13. Disconnect the electrical connection;

à p. 5 - 84.

à

p. 5 - 67.

14. Disconnect the slewing connection; This point does not apply if the rigged lattice extension is being used again for the next job and there is no need for telescoping in the meantime.

15. Remove the guide rope.

à Transport

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16. Check that the equipment is secured for transport; condition – folded, p. 5 - 11

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Swing-away lattice 5.3 Checklists for rigging work

5.3.4

CHECKLIST: Removing the swing-away lattice – from operating position

H

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

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear; Operating instructions GMK4080-2.

à

– The appropriate counterweight for operation of the crane must be Operating instructions GMK4080-2. rigged;

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– An auxiliary crane must be available.

2. For a derricking swing-away lattice:

à p. 5 - 110. à Derricking

– Lower the main boom into a horizontal position; – Derrick the swing-away lattice into the 0° position; the swing-away lattice in operation, p. 5 - 111.

3. For an inclinable swing-away lattice: Lower the main boom for unreeving the hook block.

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Swing-away lattice 5.3 Checklists for rigging work

4. If necessary, remove the anemometer and air traffic control light; p. 5 - 96.

à

5. Remove the lifting limit switch weight and lifting limit switch; Installing/removing the lifting limit switch, p. 5 - 94; Operating instructions GMK4080-2.

à à

6. If necessary, remove the camera;

7. Unreeve the hook block;

à p. 5 - 99.

à Operating instructions GMK4080-2.

8. For an inclinable swing-away lattice: Set 0° angle, if necessary; p. 5 - 102 – With auxiliary crane; – Without auxiliary crane; p. 5 - 103

à

à

à p. 5 - 91.

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9. Remove the hoist rope from the swing-away lattice;

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Swing-away lattice 5.3 Checklists for rigging work

10. For a derricking swing-away lattice: – Connect the hand-held control;

11. Fasten a guide rope;

à p. 3 - 12.

à p. 5 - 60.

To section 2 for combination A. To section 1 for combination B.

12. Fold the deflection sheave onto section 2;

à p. 5 - 89.

For combination B: – Disconnect the electrical connection between section 1–sectionl 2; p. 5 - 84.

à

– Disconnect the connection section 1–section 2, rear left;

à p. 5 - 73.

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Swing-away lattice 5.3 Checklists for rigging work

– Swing section 1 to the side of section 2;

à p. 5 - 79.

– Establish the connection section 1–section 2, front;

à p. 5 - 64.

– Fasten a guide rope to section 2.

13. Disconnect the electrical connection to the main boom;

à p. 5 - 84.

14. For a derricking swing-away lattice: – Disconnect the hydraulic connection;

à p. 5 - 83.

– If necessary, move the hoses into the position for main boom operation; p. 4 - 6.

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à

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Swing-away lattice 5.3 Checklists for rigging work

– Detach the hand-held control;

à Operating instructions GMK4080-2.

15. Sling the swing-away lattice to the auxiliary crane and fasten a guide rope;

à Slinging points, p. 5 - 4, à Secure the swing-away lattice with guide rope, p. 5 - 60.

16. Disconnect the connection to the main boom on the right and left.

To do so, relieve the strain on the connecting points, if needed. The slewing connection remains intact.

à Establishing/disconnecting the connection between the main boom/ section 2, p. 5 - 69, à Relieving the strain on the connecting points, p. 5 - 70.

17. Disconnect the slewing connection and deposit the swing-away lattice on a separate vehicle; Establishing/disconnecting the slewing connection, p. 5 - 67, Transport condition – removed, p. 5 - 8.

à à

18. If section 1 is still installed on the main boom and is also to be removed: – Sling section 1; p. 5 - 4.

à

à p. 5 - 63.

– Disconnect the connection section 1-main boom, rear; à p. 5 - 66.

– Disconnect the connection section 1-main boom, front; – Set down section 1 on the separate vehicle.

19. Remove the guide rope.

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Swing-away lattice 5.3 Checklists for rigging work

à Transport

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20. Check the transport condition of the swing-away lattice. condition – removed, p. 5 - 8

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Swing-away lattice 5.3 Checklists for rigging work

5.3.5

CHECKLIST: Removing the swing-away lattice – from transport position

G 1 5

H

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

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for operation of the crane must be rigged; Operating instructions GMK4080-2.

à

– The main boom must be completely retracted and lowered into the Operating instructions GMK4080-2. horizontal position;

à

– An auxiliary crane must be available.

2. Check that all equipment is secured in transport condition and if not, Transport condition – folded, p. 5 - 11. secure it in transport condition;

à

3. For derricking swing-away lattice Disconnect the hydraulic connection, if necessary;

à p. 5 - 83.

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Swing-away lattice 5.3 Checklists for rigging work

4. Disconnect the electrical connection to the main boom;

à p. 5 - 84.

5. Sling the swing-away lattice to the auxiliary crane and fasten a guide rope;

à Slinging points, p. 5 - 4, à Secure the swing-away lattice with guide rope, p. 5 - 60.

6. When the swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft) is folded to the side: – Disconnect the connection section 2-main boom, front; p. 5 - 61.

– Disconnect the connection section 2-main boom, rear; p. 5 - 65.

à à

7. When the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) is folded to the side: – Check that the connection section 1–section 2 rear has been made; p. 5 - 73, p. 5 - 75.

– Check that the connection section 1–section 2 front has been made; p. 5 - 64.

– Disconnect the connection section 1-main boom, rear; p. 5 - 66.

– Disconnect the connection section 1-main boom, front; p. 5 - 63.

– Disconnect the connection section 2-main boom, front; p. 5 - 61.

à

à

à

à à à

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8. Lift the swing-away lattice off the main boom and set it aside.

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Swing-away lattice 5.3 Checklists for rigging work

9. Check whether the swing-away lattice is secured for transport; Transport condition – removed, p. 5 - 8.

à

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10. Remove the guide rope.

Operating instructions for lattice extension GMK4080-2

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Swing-away lattice 5.3 Checklists for rigging work

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Blank page

5 - 34

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.3 Checklists for rigging work

5.3.6

CHECKLIST: Rigging the swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft) – in the operating position

H

This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for operation of the crane must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– The main boom is lowered to the horizontal position; instructions GMK4080-2.

2. For a derricking swing-away lattice: – If necessary, mount the hose drum;

à Operating

à p. 4 - 3.

– If necessary, check that the locking device has been released; p. 4 - 5.

à

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Swing-away lattice 5.3 Checklists for rigging work

– Connect the hand-held control;

à p. 3 - 12.

3. Check that the equipment is secured for transport; condition – folded, p. 5 - 11

4. For a derricking swing-away lattice: Establish the hydraulic connection;

5. Establish the electrical connection;

6. Establish the slewing connection;

à Transport

à p. 5 - 80.

à p. 5 - 84.

à p. 5 - 67.

7. Secure the swing-away lattice on the main boom with a guide rope; p. 5 - 60.

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à

5 - 36

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Swing-away lattice 5.3 Checklists for rigging work

8. If only section 2 is installed: – Disconnect the connection between section 2–main boom, rear; p. 5 - 65.

à

– Disconnect the connection between section 2–main boom, front; p. 5 - 61.

à

9. If section 1 and section 2 are installed: – Disconnect the connection between section 2–main boom, rear; p. 5 - 65.

à

– Establish the connection between section 1–main boom, rear;

à p. 5 - 66.

à p. 5 - 64.

– Establish the connection between section 1–main boom, front; à p. 5 - 63.

– Disconnect the connection section 1–section 2, front;

– Disconnect the connection between section 2–main boom, front; p. 5 - 61.

à

10. For a derricking swing-away lattice: Raise the swing-away lattice up to the end stop;

à p. 5 - 98.

11. Swing the swing-away lattice in front of the main boom;

à p. 5 - 77.

12. Establish the connections to the right and left of the main boom head; relieve the strain on the connecting points to do so, if necessary; Establishing/disconnecting the connection between the main boom/ section 2, p. 5 - 69, Relieving the strain on the connecting points, p. 5 - 70.

à

19.06.2019

à

13. For a derricking swing-away lattice: If necessary, move the hoses into the position for working with the lattice extension; p. 4 - 6.

à

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Swing-away lattice 5.3 Checklists for rigging work

14. Fold out the deflection sheave on section 2;

15. Position the hoist rope;

à p. 5 - 89.

à p. 5 - 91.

16. For an inclinable swing-away lattice: Set the angle position, if necessary; Setting the angle – with an auxiliary crane, p. 5 - 102.

Setting the angle – without an auxiliary crane, p. 5 - 103

à à

17. Remove the guide rope.

à p. 5 - 57.

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18. Perform subsequent necessary rigging work;

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.3 Checklists for rigging work

5.3.7

CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – in the operating position

H

This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for operation of the crane must be rigged; Operating instructions GMK4080-2.

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

– The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

à

à

2. For a derricking swing-away lattice: – If necessary, mount the hose drum;

à p. 4 - 3.

– If necessary, check that the locking device has been released; p. 4 - 5.

à

– Connect the hand-held control;

à p. 3 - 12.

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Swing-away lattice 5.3 Checklists for rigging work

3. Check that the equipment is secured for transport; condition – folded, p. 5 - 11

4. For a derricking swing-away lattice: Establish the hydraulic connection;

5. Establish the electrical connection;

6. Establish the slewing connection;

à Transport

à p. 5 - 80.

à p. 5 - 84.

à p. 5 - 67.

7. Secure the swing-away lattice on the main boom with a guide rope; p. 5 - 60.

à

8. Disconnect the connection between section 2–main boom, rear; p. 5 - 65.

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à

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Swing-away lattice 5.3 Checklists for rigging work

9. Disconnect the connection between section 2–main boom, front; p. 5 - 61.

à

10. For a derricking swing-away lattice: Raise the swing-away lattice up to the end stop;

à p. 5 - 98.

11. Swing the swing-away lattice in front of the main boom;

à p. 5 - 77.

12. Establish the connections to the right and left of the main boom head; relieve the strain on the connecting points to do so, if necessary; Establishing/disconnecting the connection between the main boom/ section 2, p. 5 - 69, Relieving the strain on the connecting points, p. 5 - 70.

à à

13. For a derricking swing-away lattice: If necessary, move the hoses into the position for working with the lattice extension; p. 4 - 6.

à

14. Fasten a guide rope to the head of section 1;

à p. 5 - 60.

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Swing-away lattice 5.3 Checklists for rigging work

15. Depending which connection is established: – Disconnect the connection section 1–section 2, front;

à p. 5 - 64, or

– Disconnect the connection between section 1–main boom, front; p. 5 - 63.

à

16. Establish the electrical connection between section 1 – section 2; p. 5 - 84.

à

17. Swing section 1 in front of section 2;

à p. 5 - 79.

18. Establish the connection between section 2 and section 1, rear left; p. 5 - 73.

à

19. Fold out the deflection sheave on section 2;

à p. 5 - 91.

12.06.2017 19.06.2019

20. Position the hoist rope;

à p. 5 - 89.

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.3 Checklists for rigging work

21. For an inclinable swing-away lattice: Set the angle position, if necessary;

à Setting the angle – with an auxiliary crane, p. 5 - 102. à Setting the angle – without an auxiliary crane, p. 5 - 103

22. Remove the guide rope.

à p. 5 - 57.

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23. Perform subsequent necessary rigging work;

Operating instructions for lattice extension GMK4080-2

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Swing-away lattice 5.3 Checklists for rigging work

12.06.2017 19.06.2019

Blank page

5 - 44

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.3 Checklists for rigging work

5.3.8

CHECKLIST: Rigging the swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft) – in the transport position

H

This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for operation of the crane must be Operating instructions GMK4080-2. rigged;

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– Section 1 must be attached and secured to the side of the main boom or separately transported.

2. For a derricking swing-away lattice:

à p. 5 - 110. à Derricking the

– Lower the main boom into a horizontal position; – Derrick the swing-away lattice into the 0° position; swing-away lattice in operation, p. 5 - 111.

3. For an inclinable swing-away lattice: Lower the main boom for unreeving the hook block.

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Swing-away lattice 5.3 Checklists for rigging work

4. If necessary, remove the anemometer and air traffic control light; p. 5 - 96.

à

5. Remove the lifting limit switch weight and lifting limit switch; Installing/removing the lifting limit switch, p. 5 - 94; Operating instructions GMK4080-2.

à à

6. If necessary, remove the camera;

à p. 5 - 99.

7. For an inclinable swing-away lattice: Set 0° angle, if necessary; p. 5 - 102 – With auxiliary crane; – Without auxiliary crane; p. 5 - 103

à

à

8. For a derricking swing-away lattice: – Connect the hand-held control;

à p. 3 - 12.

à Positions of the

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– Remove hydraulic hoses from the guide sheaves; hydraulic hoses when rigging – Before folding, p. 4 - 8.

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Swing-away lattice 5.3 Checklists for rigging work

9. Fasten a guide rope to section 2;

10. Unreeve the hook block;

à p. 5 - 60.

à Operating instructions GMK4080-2.

11. Remove the hoist rope from the swing-away lattice;

12. Fold the deflection sheave onto section 2;

à p. 5 - 91.

à p. 5 - 89.

13. Disconnect the connections to the right and left of the main boom head; relieve the strain on the connecting points to do so, if necessary. The slewing connection remains intact.

Establishing/disconnecting the connection between the main boom/ section 2, p. 5 - 69, Relieving the strain on the connecting points, p. 5 - 70.

à à

14. Swing the lattice extension onto the side of the main boom with a guide rope; p. 5 - 77.

à

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Swing-away lattice 5.3 Checklists for rigging work

15. For a derricking swing-away lattice: Lower the swing-away lattice until it rests on the console, rear; p. 5 - 98.

à

16. If only section 2 is installed: – Establish the connection between section 2–main boom, rear; p. 5 - 65.

à

– Establish the connection between section 2–main boom, front; p. 5 - 61.

à

17. If only section 1 is installed:

à p. 5 - 61.

– Establish the connection between section 2–main boom, rear; à p. 5 - 65.

– Establish the connection section 1–section 2, front; à p. 5 - 64.

– Establish the connection between section 2–main boom, front;

– Establish the connection section 1 – section 2, rear on the right-hand side; p. 5 - 75.

à

18. For a derricking swing-away lattice: – Disconnect the hydraulic connection;

19. Disconnect the electrical connection;

à p. 5 - 81.

à p. 5 - 84.

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Operating instructions for lattice extension GMK4080-2

19.06.2019

à

p. 5 - 67.

20. Disconnect the slewing connection; This point does not apply if the rigged lattice extension is being used again for the next job and there is no need for telescoping in the meantime.

Swing-away lattice 5.3 Checklists for rigging work

21. Remove the guide rope.

22. For a derricking swing-away lattice: Detach the hand-held control;

à Operating instructions GMK4080-2.

à Section 1 only,

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23. Check that the equipment is secured for transport; p. 5 - 11

Operating instructions for lattice extension GMK4080-2

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Swing-away lattice 5.3 Checklists for rigging work

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Blank page

5 - 50

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.3 Checklists for rigging work

5.3.9

CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – in the transport position

H

This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for operation of the crane must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

2. For a derricking swing-away lattice:

à p. 5 - 110. à Derricking the

– Lower the main boom into a horizontal position; – Derrick the swing-away lattice into the 0° position; swing-away lattice in operation, p. 5 - 111.

3. For an inclinable swing-away lattice: Lower the main boom for unreeving the hook block.

4. If necessary, remove the anemometer and air traffic control light; p. 5 - 96.

19.06.2019

à

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Swing-away lattice 5.3 Checklists for rigging work

5. Remove the lifting limit switch weight and lifting limit switch; p. 5 - 94; Operating instructions GMK4080-2.

à à

6. If necessary, remove the camera;

à p. 5 - 99.

7. For a derricking swing-away lattice: Connect the hand-held control;

8. Unreeve the hook block;

à p. 3 - 12.

à Operating instructions GMK4080-2.

9. For an inclinable swing-away lattice: Set 0° angle, if necessary; p. 5 - 102 – With auxiliary crane; – Without auxiliary crane; p. 5 - 103

à

à

à p. 5 - 91.

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10. Remove the hoist rope from the swing-away lattice;

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Swing-away lattice 5.3 Checklists for rigging work

11. Fasten a guide rope to section 1;

à p. 5 - 60.

12. Fold the deflection sheave onto section 2;

à p. 5 - 89.

13. Disconnect the electrical connection between section 1 – section 2; p. 5 - 84.

à

14. Disconnect the connection section 1–section 2, rear left;

15. Swing section 1 to the side of section 2;

à p. 5 - 73.

à p. 5 - 79.

16. Establish the connection section 1–section 2, front;

à p. 5 - 64.

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Swing-away lattice 5.3 Checklists for rigging work

17. Fasten a guide rope to section 2.

18. For a derricking swing-away lattice: Remove hydraulic hoses from the guide sheaves; à Positions of the hydraulic hoses when rigging – Before folding, p. 4 - 8.

19. Disconnect the connections to the right and left of the main boom head; relieve the strain on the connecting points to do so, if necessary.

The slewing connection remains intact.

Establishing/disconnecting the connection between the main boom/ section 2, p. 5 - 69, Relieving the strain on the connecting points, p. 5 - 70.

à à

20. Swing the lattice extension onto the side of the main boom with a guide p. 5 - 77. rope;

à

à p. 5 - 65.

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21. Establish the connection between section 2–main boom, rear;

5 - 54

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Swing-away lattice 5.3 Checklists for rigging work

22. Establish the connection between section 2–main boom, front; p. 5 - 61.

à

23. For a derricking swing-away lattice: – Disconnect the hydraulic connection to the main boom;

24. Disconnect the electrical connection to the main boom;

à p. 5 - 81.

à p. 5 - 85.

à

25. Disconnect the slewing connection; p. 5 - 67.

This point does not apply if the rigged lattice extension is being used again for the next job and there is no need for telescoping in the meantime.

26. For a derricking swing-away lattice: Detach the hand-held control;

à Operating instructions GMK4080-2.

27. Remove the guide rope.

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5 - 55

Swing-away lattice 5.3 Checklists for rigging work

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28. Check the transport condition of the swing-away lattice.

5 - 56

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.3 Checklists for rigging work

5.3.10

CHECKLIST: Further rigging work

H

This checklist is not a complete operating manual. There are accompanying instructions, which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The rigging work specified in the corresponding checklist has been correctly performed.

2. Mount the anemometer and if necessary the air traffic control light; p. 5 - 96.

à

3. If necessary, mount the camera;

à p. 5 - 99.

4. Reeve the hoist rope on the hook block; GMK4080-2.

à Operating instructions

5. Install the lifting limit switch, attach the lifting limit switch weight and place it around the hoist rope; p. 5 - 94; Operating instructions GMK4080-2.

à à

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5 - 57

Swing-away lattice 5.3 Checklists for rigging work

6. For a derricking swing-away lattice: Detach the hand-held control;

à Operating instructions GMK4080-2.

7. Check the horizontal alignment of the truck crane and correct, if necessary.

8. Enter the current rigging mode with the rigged swing-away lattice; Setting the RCL, p. 5 - 109.

à

à Setting the RCL, p. 5 - 109.

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9. Enter current reeving;

5 - 58

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Swing-away lattice 5.4 Rigging work

5.4

Rigging work

5.4.1

Notes on the position of the telescoping cylinder The connections (1) to (3) must line up at the applicable rigging step, according to the swing-away lattice being used.

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The brackets on the main boom are set so that the connections line up when the main boom is fully retracted and all telescopic sections are set down.

After retracting, additionally lock the telescoping cylinder in telescopic section V in order to secure this position.

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5 - 59

Swing-away lattice 5.4 Rigging work

5.4.2

G

Secure the swing-away lattice with guide rope Risk of accidents due to sections swinging of their own accord Always fasten a guide rope to the sections being swung before you unlock or separate the connections.

An extra person must keep the guide rope tightly tensioned or you must fasten the guide rope so that the sections cannot swing unintentionally when the necessary connections are unlocked or separated.

Fasten the guide rope to section 1

• Fasten the guide rope behind the head of section 1 (1).

Fasten the guide rope to section 2

• Fasten the guide rope to the swing-away lattice A or B, for example to the rope attachment point (1).

(A) – For pivoting onto the main boom

• Attach the guide rope to the rope attachment point (1).

• Guide the rope underneath the swing-away lattice, over the rope guide (2) on the main boom and back again.

(B) – For pivoting in front of the main boom head

• Attach the guide rope to the rope

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attachment point (1).

5 - 60

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Swing-away lattice 5.4 Rigging work

5.4.3

Establish/disconnect the connection section 2–main boom, front Prerequisites: – The main boom must be fully retracted.

– A guide rope must be attached.

Connecting

• Remove the pin (1) from the holder (3).

• Insert the pin (1) into the connecting point (2).

• Secure the pin.

Disconnecting

G

Risk of accidents from a falling lattice extension Before disconnecting, make sure that the slewing connection is established; p. 5 - 67.

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

à

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5 - 61

Swing-away lattice 5.4 Rigging work

• Remove the pin (1) from the connecting point (2).

• Insert the pin (1) into the holder (3).

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• Secure the pin.

5 - 62

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Swing-away lattice 5.4 Rigging work

5.4.4

Section 1/main boom, front – establish/disconnect the connection Prerequisites: – The main boom must be fully retracted.

– A guide rope must be attached.

Connecting

• Remove the pin (2) from the connecting point (1).

• Insert the pin (2) into the connecting point (3).

• Secure the pin.

Disconnecting

The connection must be disconnected when section 1 alone is installed on the main boom and is to be removed.

• Sling section 1 onto an auxiliary crane.

• Remove the pin (2) from the connecting point (3).

• Insert the pin (2) into the holder (1).

• Secure the pin.

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• Lift section 1 from the main boom.

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5 - 63

Swing-away lattice 5.4 Rigging work

5.4.5

Section 1/section 2, front – establish/disconnect the connection Prerequisites: – The main boom must be fully retracted.

– A guide rope must be attached.

Connecting Establishing the connection • Remove the pin (2) from the connecting point (3).

• Insert the pin (2) into the connecting point (1).

• Secure the pin.

Disconnecting

• Remove the pin (2) from the connecting point (1).

• Insert the pin (2) into the connecting point (3).

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• Secure the pin.

5 - 64

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

5.4.6

Section 2/main boom, rear – establish/disconnect the connection Prerequisites: – The main boom must be fully retracted.

– A guide rope must be attached.

Connecting

This connection is made during unrigging, after the swing-away lattice is folded to the side.

(A) – Before folding the lattice extension to the side:

• Take the pin (1) out of the connecting point (2) or (3).

(B) – Once the lattice extension is folded to the side:

• Insert the pin (1) into the connecting point (2).

• Secure the pin.

Disconnecting

The connection is disconnected when rigging, before the swing-away lattice is swung.

(A) – Before the swing-away lattice is swung in front of the main boom:

• Remove the pin (1) from the connecting point (2).

(B) – After the swing-away lattice has been swung to the side of the main boom:

• Insert the pin (1) into the connecting point (2) or (3).

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• Secure the pin.

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5 - 65

Swing-away lattice 5.4 Rigging work

5.4.7

Section 1/main boom, rear – establish/disconnect the connection

Connecting

This connection is made if the 1.2 + 7.5 m (3.9 + 24.6ft) swing-away lattice extension is rigged and section 1 is installed on the main boom.

(A) – Before folding the lattice extension to the side:

• Take the pin (1) out of the connecting points (2) or (3).

(B) – Once the lattice extension is folded to the side:

• Insert the pin (1) into the connecting point (2).

• Secure the pin.

Disconnecting

The connection is disconnected: – Before the 1.2 + 13.8 m (3.9 + 45.3 ft) swing-away lattice is swung in front of the main boom head while rigging, or – If only section 1 is to be removed from the main boom

• (A) – Take the pin (1) out of the connecting point (2) or (3).

(B) – If the swing-away lattice is swung in front of the boom head:

• Insert the pin (1) into the connecting points (2) or (3).

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• Secure the pin.

5 - 66

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Swing-away lattice 5.4 Rigging work

5.4.8

G

Establishing/disconnecting the slewing connection Risk of accidents if used improperly Attach slings to the swing-away lattice only at the designated slinging points. Use only lifting gear and joining elements of sufficient load bearing capacity.

Prerequisites: – The main boom must be fully retracted.

– A guide rope must be attached.

– The inclinable swing-away lattice is in the 0° position; p. 5 - 103.

à

à p. 5 - 102 or

Connecting

• Remove the pins (1) from the holders (3) and insert them into the connecting points (2).

• Secure the pins.

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5 - 67

Swing-away lattice 5.4 Rigging work

Disconnecting

G

Risk of accidents due to the swing-away lattice falling Ensure that the swing-away lattice is slung on an auxiliary crane or attached to the main boom before separating the slewing connection. This prevents the swing-away lattice from falling down and injuring or killing you or other persons.

• Remove the pins (1) from the connecting points (2) and insert them into the holders (3).

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• Secure the pins.

5 - 68

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

5.4.9

Establishing/disconnecting the connection between the main boom/section 2 – The swing-away lattice is slung on an auxiliary crane and us handing in front of the main boom or – the swing-away lattice is swivelled in front of the main boom.

– A guide rope must be attached.

G

Risk of accidents due to swinging sections Always secure the sections with a guide rope from the ground before establishing or disconnecting connections.

This prevents you from being crushed or caught by swinging sections.

Connecting If the pins cannot be inserted, you can relieve the strain on the connecting points; p. 5 - 70.

à

• Align the connecting points (2).

• Remove the pins (1) from the holders (3) and insert them into the connecting points (2).

• Secure the pins.

Disconnecting If the pins cannot be inserted, you can relieve the strain on the connecting points; p. 5 - 70.

à

• Make sure that the pin (2) is in the slewing connection and is secured.

• Check that the electrical and hydraulic connections have been disconnected.

• First disconnect the connection on the 19.06.2019

right-hand side.

• Remove the pins (1) from the connecting points (2) and insert them into the holders (3).

• Secure the pins.

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5 - 69

Swing-away lattice 5.4 Rigging work

5.4.10

Relieving the strain on the connecting points

For derricking swing-away lattice

• Derrick the swing-away lattice until its skids are resting on the ground (2) (if necessary, override the lifting limit switch).

• Continue to derrick carefully until the connecting points (1) align or until the pins have been relieved of strain; Derricking the swing-away lattice for rigging work – hand-held control, p. 5 - 98, Derricking the swing-away lattice – Section 2 control unit, p. 5 - 101.

à à

For a derricking swing-away lattice without hydraulic rigging aid

• Sling section 2 onto an auxiliary crane.

• Carefully raise the swing-away lattice until

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the connecting points (1) align or until the strain on the pins has been relieved.

5 - 70

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

For a derricking swing-away lattice with hydraulic rigging aid The hydraulic cylinder (2) is operated with the hand pump (1) to push the swing-away lattice away from the main boom until the pin (3) can be inserted.

When rigging Prerequisites: – The connection (5) is established. The pin is secured.

• Close the valve (2) (turn to the right).

• Move the lever (1) backwards and forwards.

The ram of the hydraulic cylinder (3) extends. Move the lever (1) until the holes are aligned at the connecting point (4).

• Fit the pin on the connecting point (4) and secure it.

• Open the valve (2) (turn to the left).

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5 - 71

Swing-away lattice 5.4 Rigging work

When unrigging

• First pull the pin out of the connecting point (4).

If the pin cannot be pulled out, relieve the strain on the pin.

• Close the valve (2).

• Move the lever (1) backwards and forwards.

The ram of the hydraulic cylinder (3) extends. Move the lever (1) until the strain on the pin at the connecting point (4) is relieved.

• Insert the pin from the connecting point (4) in the holder (5) and secure it there.

• Slowly open the valve (2).

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Insert the pin from the connecting point (7) in the holder (6).

5 - 72

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Swing-away lattice 5.4 Rigging work

5.4.11

G G

Section 1/section 2 – Establish/disconnect the left-hand connection Risk of accidents due to falling parts Ensure that all necessary connections have been established as specified in the checklist before disconnecting this connection.

This prevents any swing-away lattice sections from falling down during swinging, or when the main boom is raised later.

Risk of accidents due to section 1 swinging of its own accord Always approach the connecting point from the left side only and position a ladder only on the left on section 2.

This prevents section 1 from swinging of its own accord and crushing you or knocking you off the ladder.

A guide rope must be attached to section 1;

à p. 5 - 60.

Establishing the connection The connection is established after section 1 is swung in front of section 2.

• Remove the pins (1) from the holders (3).

• Insert the pins (1) into the connecting points (2).

• Secure the pins.

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5 - 73

Swing-away lattice 5.4 Rigging work

Disconnecting the connection The connection is disconnected before section 1 is folded onto the side of section 2.

• Remove the pins (1) from the connecting points (2).

• Insert the pins (1) into the holder (3).

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• Secure the pins.

5 - 74

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Swing-away lattice 5.4 Rigging work

5.4.12

G G

Section 1/section 2 – Establish/disconnect the right-hand connection Risk of accidents due to falling section Ensure that all necessary connections have been established as specified in the checklist before disconnecting this connection.

This prevents section 1 from falling when swinging.

Risk of accidents due to section 2 swinging of its own accord Always approach the connecting point from the left side only and do not position a ladder on section 2.

This prevents section 2 from swinging and knocking you off the ladder.

A guide rope must be attached to section 2;

à p. 5 - 60.

Establishing the connection The connection is established after section 2 is swung onto section 1.

• Remove the pin (1) from the holder (3).

• Insert the pins into the connecting points (2).

• Secure the pins.

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5 - 75

Swing-away lattice 5.4 Rigging work

Disconnecting the connection The connection is disconnected before section 2 is folded in front of the main boom.

• Remove the pins (1) from the connecting points (2).

• Insert the pins into the holder (3).

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• Secure the pins.

5 - 76

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

5.4.13

G S

Swinging the swing-away lattice Risk of accidents due to uncontrolled swinging of the swing-away lattice Ensure that no people or objects are in the swinging range and always swing the swing-away lattice with a guide rope from the ground.

Risk of damage to electrical and hydraulic connections Ensure that the hydraulic and electrical connections are not trapped/ jammed when swinging.

A guide rope must be attached to section 2;

à p. 5 - 60.

Swinging the swing-away lattice in front of the main boom head

• Ensure that: – With combination B, the connection section 1–section 2, front (1) is established; p. 5 - 64.

– The slewing connection (2) is established, p. 5 - 67.

à

à

• Swing the swing-away lattice in front of the main boom head using the guide rope so that the connecting points (1) line up.

• An extra person must keep the guide rope tightly tensioned or you must fasten the guide rope so that the swing-away lattice cannot swing back before the connection between the swing-away lattice and the main boom has been established; p. 5 - 69.

à

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5 - 77

Swing-away lattice 5.4 Rigging work

Swinging the swing-away lattice on to the main boom

• Before swinging the swing-away lattice on to the main boom, you must ensure that: – With a derricking swing-away lattice: the 0° angle is set on the p. 5 - 98, derricking cylinder (1);

à

– With an inclinable swing-away lattice: the 0° angle (2) is set; p. 5 - 102.

à

– With combination B, the connection section 1–section 2, front (1) is established; p. 5 - 64.

à

• Swing the swing-away lattice onto the main boom using the guide rope so that the connection section 2–main boom, rear (1) can be established and secured.

• Do not disconnect the slewing connection (2) until the connection

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section 2–main boom, rear (1) has been established and secured.

5 - 78

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

5.4.14

G S

Swinging section 1 Risk of accidents through section 1 swinging round Ensure that no people or objects are in the slewing range of the section and always swing section 1 with a guide rope from the ground.

Risk of damage to the electrical connection Ensure that the electrical connection is not trapped/jammed when swinging.

A guide rope must be attached to section 1;

à p. 5 - 60.

Swing section 1 in front of section 2

• Disconnect the connection section 1–section 2, front (1); à p. 5 - 64.

• Swing section 1 in front of section 2 using the guide rope so that the connecting points line up.

• An extra person must keep the guide rope tightly tensioned or you must fasten the guide rope so that section 1 cannot swing back before the connection (1) between the sections has been established.

Swinging section 1 against section 2

• Swing section 1 against section 2 using the guide rope.

• An extra person must keep the guide rope tightly tensioned or you must

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fasten the guide rope so that section 1 cannot swing back before the connection section 1–section 2, front (1) between the sections has been established.

Operating instructions for lattice extension GMK4080-2

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5 - 79

Swing-away lattice 5.4 Rigging work

5.4.15

G

Establishing/disconnecting the hydraulic connection – when rigging Risk of crushing due to swinging lattice extension Start the subsequent work only if the lattice extension is locked in front of the main boom head or it is secured against swinging around.

This will prevent the lattice extension from swinging inadvertently to the side of the main boom and possibly crushing you.

Connecting

• Remove the caps from the connections (2) in the holder (1).

• Connect the hydraulic hoses (3) to the connections (2) (note colour marking).

• Do not place the hydraulic hoses in the

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guide sheaves (4).

5 - 80

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

Disconnecting

S

Risk of damage to the swing-away lattice If the derricking swing-away lattice is folded to the side on the main boom, the hydraulic connection must be disconnected. If the hydraulic connection is not disconnected, the foot section can lower itself down on its own. If the main boom is then retracted, the head sheave axles knock against the foot section.

If the hydraulic connection is disconnected, the foot section cannot lower itself down on its own.

• Detach the hoses (3) from the connections (2).

• Place the connections (2) in the holder (1).

• Put the connections (4) under the hoses (3).

• Use the caps to close the hoses (2) and the

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connections (4).

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5 - 81

Swing-away lattice 5.4 Rigging work

5.4.16

Establishing/disconnecting the hydraulic connection – when installing Use the method shown below for establishing/disconnecting the hydraulic connection only when installing or removing the swing-away lattice with an auxiliary crane.

Connecting

• If necessary, bring the connections (1) into the position Working with the lattice extension, p. 4 - 6.

• Remove the caps (2).

• Connect the hydraulic hoses (3) to the connections (1) (note colour marking).

• Stow the hoses in the holder (4) so they do

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not sag.

5 - 82

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

Disconnecting

S

Risk of damage to the swing-away lattice If the derricking swing-away lattice is folded to the side on the main boom, the hydraulic connection must be disconnected. If the hydraulic connection is not disconnected, the foot section can lower itself down on its own. If the main boom is then retracted, the head sheave axles knock against the foot section.

If the hydraulic connection is disconnected, the foot section cannot lower itself down on its own.

• Disconnect the hoses (3) from the connections (1).

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

• Put the connections (2) under the hoses (3).

• Use the caps to close the hoses (3) and the connections (2).

• If necessary, bring the connections (1) into

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the position Main boom operation, p. 4 - 7.

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5 - 83

Swing-away lattice 5.4 Rigging work

5.4.17

G

Establishing/disconnecting electrical connections

Risk of crushing due to movement of swing-away lattice Always lock the swing-away lattice or secure it to prevent it from swinging before you start establishing or disconnecting electrical connections.

This prevents the swing-away lattice from swinging and crushing you.

Section 2 – Main boom Section 2 – section 1

à p. 5 - 85 à p. 5 - 87

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1 2

5 - 84

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

Section 2 – Main boom Establishing the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket (5) and plug it into the socket (1).

• Lay the cable (3) in such a way that it will not be damaged during crane operation and when swinging the swing-away lattice.

Connecting the camera

• Unwind the cable (3) from the holder (4).

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

• Lay the cable (3) in such a way that it will not be damaged during crane operation and when swinging the swing-away lattice.

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5 - 85

Swing-away lattice 5.4 Rigging work

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and place it in the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

Disconnecting the camera

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

• Wind the cable (3) onto the holder (4).

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• Cover the plug and socket with caps.

5 - 86

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

Section 1 – section 2 Establishing the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket (4) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Connecting the camera

• Unwind the cable (3) from the holder (4).

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

• Lay the cable (3) so that it will not be damaged during crane operation.

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5 - 87

Swing-away lattice 5.4 Rigging work

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and place it in the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

S

Risk of damage to the cable Always disconnect the electrical connection before you swing section 1 on to section 2. In this way, you prevent the cable from being severed during swinging.

Disconnecting the camera

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

• Wind the cable (3) onto the holder (4).

• Close the plug (2) and the socket (1) with

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caps.

5 - 88

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

5.4.18

Fold the deflection sheave in/out on section 2

Folding out

G

Risk of crushing Always hold the deflection sheaves on section 2 firmly by the handle when removing the pin.

Your fingers can be crushed if you hold a sheave by the side panel.

• (A) – Hold the deflection sheave firmly by the handle (1) and pull out the pin (2).

• (B) – Fold the deflection sheave (3) upwards and fasten it in that position with the pin (2).

• Secure the pin (2) using the retaining pin.

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5 - 89

Swing-away lattice 5.4 Rigging work

Folding in

G G

You must fold in the deflection sheaves in order to drive with a folded swing-away lattice.

Risk of accidents by exceeding total permissible height Fold in the deflection sheaves when the swing-away lattice is folded on the main boom for driving. When the deflection sheave is folded out, the overall height specified for on-road driving is exceeded.

Risk of crushing Always hold the deflection sheave firmly by the handle when removing the pin. You might get your fingers crushed if you hold the sheave by the side plate.

• (A) – Hold the deflection sheave firmly by the handle (1) and pull out the pin (2).

• (B) – Fold the deflection sheave (3) downwards and fasten it in that position with the pin (2).

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• Secure the pin (2) using the retaining pin.

5 - 90

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

5.4.19

Attaching/removing the hoist rope You can use the rigging hook for this;

G

à p. 3 - 13.

Risk of accidents due to falling parts Always secure the sheaves and rods for securing the hoist rope with retaining pins.

This prevents elements from coming loose or falling and causing injuries.

Fitting

• Remove the sheaves (6) and rods (6).

• Guide the hoist rope over the deflection sheaves (1), (2) and (4) or (1), (2) and (3).

• Install all sheaves (6) and rods (6).

• Secure all the rods (6).

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s Operating instructions for lattice extension GMK4080-2

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5 - 91

Swing-away lattice 5.4 Rigging work

Removing

• Remove the sheaves (6) and rods (6).

• Remove the hoist rope from the deflection sheaves (1), (2) and (4) or (1), (2) and (3).

• Lay the hoist rope down on the ground at the left-hand side or roll it onto the drum up to the main boom head/hoist.

• Install all sheaves (1) and rods (1).

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• Secure all the rods (1).

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

Reeving options

Reeving the hoist rope into the hook block; Operating instructions GMK4080-2.

à

1-sheave hook block Reeving A

2-fall

B

1-fall

Hook tackle Reeving C

1-fall

• Combination A only – With 2-fall reeving, fasten the rope end clamp to the

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rope attachment point (1).

Operating instructions for lattice extension GMK4080-2

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Swing-away lattice 5.4 Rigging work

5.4.20

Installing/removing the lifting limit switch

Installing

If only a single lifting limit switch is available you must use the lifting limit switch belonging to the main boom; Operating instructions GMK4080-2.

à

If several lifting limit switches are available, you must override all the lifting limit switches connected to the main boom which do not have a lifting limit switch weight suspended from them; Operating instructions GMK4080-2.

à

On section 1

• Plug the lifting limit switch (4) onto the holder (3).

• Secure the lifting limit switch.

• Fasten the cable so that it will not sag during crane operation and potentially be damaged.

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

• Install the lifting limit switch weight (5) and lay it around the hoist rope; instructions GMK4080-2.

à Operating

On section 2

• Plug the lifting limit switch (4) onto the holder (3).

• Secure the lifting limit switch.

• Fasten the cable so that it will not sag during crane operation and potentially be damaged.

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

• Install the lifting limit switch weight (5) and

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lay it around the hoist rope; à Operating instructions GMK4080-2.

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

Removing From section 1

• Remove the lifting limit switch weight (5);

à Operating instructions GMK4080-2.

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

• Cover the socket (1) with the cap.

• Remove the lifting limit switch (4) from the holder (3).

• Stow the lifting limit switch so that it is safe when driving on roads, or install it on the main boom; Operating instructions GMK4080-2.

à

From section 2

• Remove the lifting limit switch weight (5);

à Operating instructions GMK4080-2.

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

• Cover the socket (1) with the cap.

• Remove the lifting limit switch (4) from the holder (3).

• Stow the lifting limit switch so that it is safe when driving on roads, or install it on the main boom; Operating instructions GMK4080-2.

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à

Operating instructions for lattice extension GMK4080-2

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5 - 95

Swing-away lattice 5.4 Rigging work

5.4.21

Installing/removing the anemometer and air traffic control light

Installing

The anemometer and the air traffic control light – if provided – are located on the same rod.

On section 1

• Insert the rod (5) into the clamp (3) and secure it.

• Remove the cables from the holders (4) and connect: – The anemometer to socket (2) – The air traffic control light to socket (1)

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

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

On section 2

• Insert the rod (5) into the clamp (3) and secure it.

• Remove the cables from the holders (4) and connect: – The anemometer to socket (2) – The air traffic control light to socket (1)

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

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

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Switching the air traffic control light on and off; à Operating instructions GMK4080-2.

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

Removing

You must remove the rod with the anemometer/air traffic control light before driving on the road.

• Switch off the air traffic control light.

From section 1

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

• Wind the cables onto the holders (4).

• Remove the rod (5) from the clamp (3).

• Stow away the anemometer so that it is safe when driving on roads; à Operating instructions GMK4080-2.

From section 2

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

• Wind the cables onto the holders (4).

• Remove the rod (5) from the clamp (3).

• Stow away the anemometer so that it is safe

à Operating

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when driving on roads; instructions GMK4080-2.

Operating instructions for lattice extension GMK4080-2

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5 - 97

Swing-away lattice 5.4 Rigging work

5.4.22

Derricking the swing-away lattice for rigging work – hand-held control Derricking the swing-away lattice in operation;

à p. 5 - 111.

Before derricking the lattice extension, enter an RCL code for working with the lattice extension so that derricking will be enabled; Setting the RCL, p. 5 - 109.

à

The button (1) is only active when the swing-away lattice is connected electrically.

• Press the button (1) – the engine will start.

Pre-select the lattice extension derricking gear • Press the button (1).

– The lamp in the button lights up.

Derricking the swing-away lattice

• Press the button combination for the desired movement: 1 Raise swing-away lattice 2 Lower swing-away lattice The further you press the button (1) or (2) in, the faster the movement.

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The pre-selected movement will be executed until you let go of the respective button or until the respective end position has been reached.

5 - 98

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Swing-away lattice 5.4 Rigging work

5.4.23

Installing/removing the camera Operating the camera;

à Operating instructions GMK4080-2.

Installing On section 1

• Insert the camera (2) into the holder (1) and secure it.

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

• Lay the cable (5) so that it will not be damaged during crane operation.

On section 2

• Insert the camera (2) into the holder (1) and secure it.

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

• Lay the cable (5) so that it will not be damaged during crane operation.

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Swing-away lattice 5.4 Rigging work

Removing From section 1

• Take the plug (3) out of the socket (4) and close the socket with the cap.

• Remove the camera (2) from the holder (1) and fasten the retaining pin on the holder.

• Stow away the camera so that it will not be damaged.

From section 2

• Take the plug (3) out of the socket (4) and close the socket with the cap.

• Remove the camera (2) from the holder (1) and insert the retaining pin in the holder.

• Stow away the camera so that it will not be

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damaged.

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

5.4.24

Derricking the swing-away lattice – Section 2 control unit The control unit (1) provides an additional way of raising/lowering the swing-away lattice.

The control unit moves when derricking, which means that derricking should preferably be operated via the hand-held control or from the crane cab.

The control unit should only be used for relieving the strain on the connecting points between the swing-away lattice and main boom, when the swing-away lattice is set down with its skids (2) on the ground or for carefully setting the skids onto the ground after the swing-away lattice has been derricked almost to the ground using another control unit.

G G

Risk of crushing due to swing-away lattice movements Take care to ensure that your feet, fingers or hands are not crushed when raising/lowering the swing-away lattice.

Risk of accidents due to swing-away lattice movements Perform derricking standing next to the derricking area with both feet on the ground and derrick the swing-away lattice only within a small area above the ground that you can easily reach. Do not use a ladder.

This prevents the swing-away lattice from knocking you off the ladder and also prevents you from falling of the ladder as you follow the control unit during derricking.

Prerequisite – The electrical connections between the swing-away lattice and the main boom have been established; p. 5 - 84.

à

Derricking the swing-away lattice Raising:

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Lowering:

• Press the button (1) – the swing-away lattice is raised.

• Press the button (2) – the swing-away lattice is lowered.

The swing-away lattice is raised or lowered until you release the button or an end position is reached.

Operating instructions for lattice extension GMK4080-2

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5 - 101

Swing-away lattice 5.4 Rigging work

5.4.25

Setting the angle – with an auxiliary crane This section applies only to the inclinable swing-away lattice.

G

Risk of accidents due to swing-away lattice folding down Always secure the swing-away lattice with an auxiliary crane or by setting it down on the ground before removing the pin for angling from its hole.

In this way, you prevent the swing-away lattice from suddenly unfolding downwards and causing personal injury.

• Lift the swing-away lattice using an auxiliary crane.

• Remove the pin (1) from its hole.

• Insert the pin (1) for the desired angle into the corresponding hole.

Angle (°)

Hole

0

(2)

20

(3)

40

In the holder (4)

• Secure the pin.

• Lower the swing-away lattice down or lift it up.

• Remove the lifting gear.

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If the swing-away lattice now touches the ground at the set angle, then the angle will set itself when the main boom is raised.

5 - 102

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

5.4.26

Setting the angle – without an auxiliary crane If an auxiliary crane is not available, the swing-away lattice must be set down before the angle is set.

S Enter the RCL code

Risk of damage to the hoist rope Unreeve the hook block and set down the hoist rope beside the swing-away lattice before you angle the swing-away lattice.

In this way you prevent the hoist rope from being damaged when the head of the swing-away lattice is set down on the ground for angling.

For angling without an auxiliary crane, you must enter the RCL code for working with the lattice extension installed.

When angling without an auxiliary crane, comply with the specifications in the section Rigging tables – lattice extension in the lifting capacity tables. Among other information, this specifies the possible telescoping statuses and the maximum lifting capacity.

G G

Risk of overturning with impermissible rigging mode Always enter the RCL code for the current rigging mode of the truck crane, and only slew the superstructure into the operating position permitted by the RCL rigging code set according to the lifting capacity table.

This prevents the truck crane from overturning when the main boom is telescoped out.

Risk of overturning with raised hook block (hook tackle) The telescoping range which is enabled with the set RCL code is only permitted for telescoping without a load and without a hook block/hook tackle.

When the main boom is fully extended, load measurement is not possible and the RCL monitoring depends on the working radius.

For this reason, always unreeve the hook block. This prevents the truck crane from overturning when the main boom is telescoped out.

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Swing-away lattice 5.4 Rigging work

Setting the angle

G G

This section assumes that the swing-away lattice has been locked in front of the main boom and the unreeved hoist rope has been set down beside the swing-away lattice.

Risk of accidents if this procedure is not followed For the procedure described here, the swing-away lattice must be set down on the ground. If the swing-away lattice is to be set down on blocking for the purpose of setting the angle of inclination, please bear in mind that the swing-away lattice will slide towards the truck crane when raised, until the angle is reached.

When this happens, the swing-away lattice could slip off unsuitable blocking, and fold down and cause personal injury.

Risk of accidents when the RCL is overridden Never override the RCL if the crane movements are switched off. In this way you prevent the superstructure from being slewed out of the permissible working range and the truck crane tipping over as a result.

• Enter the correct RCL code for the current rigging mode of the truck crane;

à Lifting capacity table.

• Slew the superstructure into an operating position permitted by the lifting capacity table for the RCL rigging code set.

H

The following diagrams each show an example of a crane.

• Telescope out the main boom as far as is permitted for the RCL rigging code set, or as far as possible given the space available.

• Lower the main boom until the head of the swing-away lattice touches the ground.

• If the ground cannot be reached, you can

à p. 5 - 108.

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incline the truck crane further;

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

H

In the steps which follow, the head of the swing-away lattice is pulled or pushed over the ground. Lay some kind of support such as boards under the skids so that the head is not pushed into the ground or damaged.

• If necessary, relieve the strain on the pin (1) by derricking in slightly.

• Move the pin (1) into the position for the angle required, e.g. for angle of 20°; Setting the angle – with an auxiliary crane, p. 5 - 102.

à

• Raise the main boom slowly.

When doing so, the head of the swing-away lattice will be pulled across the ground.

• Raise the main boom until the swing-away lattice head is no longer touching the ground.

The swing-away lattice will then be inclined by the angle set, e.g. 20°.

If you inclined the truck crane using the outriggers in order to set the angle, align it to the horizontal again.

• Fully retract the main boom. While doing so, the swing-away lattice must not touch the ground (raise now and then by derricking if necessary).

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5 - 105

Swing-away lattice 5.4 Rigging work

• Set the head of the swing-away lattice down on the ground.

• Slowly lower the main boom into a horizontal position.

When doing so, the head of the swing-away lattice will be pushed across the ground.

The swing-away lattice is now in the right position for attaching the hoist rope.

G Setting a 0° angle

Risk of overturning when truck crane is standing at an angle After setting the angle, always check whether the truck crane is aligned to the horizontal.

In this way you prevent the actual working range differing from the permitted working range, leading to the truck crane tipping over.

The section assumes that no load has been raised and that the hook block has been unreeved.

• Set the head of the swing-away lattice down on the ground.

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H

In the steps which follow, the head of the swing-away lattice is pulled or pushed over the ground. Lay some kind of support such as boards under the skids so that the head is not pushed into the ground or damaged.

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.4 Rigging work

• Slowly lower the main boom into a horizontal position.

When doing so, the head of the lattice extension will be pushed across the ground.

• Remove the hoist rope (1) and set it down beside the swing-away lattice.

• Slowly lower the main boom until the swing-away lattice head is no longer touching the ground.

• Telescope out the main boom as far as is permitted for the RCL rigging code set, or as far as possible given the space available.

• Lower the main boom until the head of the swing-away lattice touches the ground.

• If the ground cannot be reached, you can incline the truck crane further;

à p. 5 - 108.

• Slowly lower the main boom until the 0° angle is reached.

When doing so, the head of the swing-away lattice will be pushed across the ground.

• Put the pin (1) of the angle piece into the

position for a 0° angle; à Setting the angle – with an auxiliary crane, p. 5 - 102.

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s Operating instructions for lattice extension GMK4080-2

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5 - 107

Swing-away lattice 5.4 Rigging work

• Derrick the main boom into the horizontal position and retract it completely.

The swing-away lattice is now in the right position to continue unrigging.

H Inclining the truck crane

If you inclined the truck crane using the outriggers, align it to the horizontal now so that the swing-away lattice sections can be folded more easily.

For inclining, you must set the swing-away lattice down on the ground by extending and lowering the main boom.

Depending on the space available, the condition of the terrain or a limitation on telescoping due to the current rigging mode, it may not be possible to set down the swing-away lattice on the ground by telescoping and lowering the main boom.

In this case, you can use the outriggers to incline the truck crane.

G

Risk of accidents if the wheels touch the ground Make sure that the wheels do not touch the ground when the truck crane is inclined. In this way you prevent a reduction in the stability of the truck crane, which could lead to it tipping over when setting the angle.

• Extend the supporting cylinders on the counterweight side.

• Retract the supporting cylinders on the main boom side, if necessary.

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Be sure that the wheels do not touch the ground when doing this.

5 - 108

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.5 Operation with swing-away lattice

5.5

Operation with swing-away lattice The raising, lowering, slewing and derricking movements and telescoping of the main boom are carried out in the same way as for operation with the main boom. This section only contains information that you will additionally need with a swing-away lattice rigged or installed.

5.5.1

Setting the RCL

Input

• On the RCL, enter the current rigging mode for operation with a rigged swing-away lattice. Do so either using the corresponding RCL code in accordance with the lifting capacity table (1) or via individual components (2).

When you input the current rigging mode via the individual components, you must also input: – the length before the angle (1) and – the length after the angle (2). and for the inclinable swing-away lattice: – the set angle of the lattice extension (3).

• On the RCL, enter the current reeving on the swing-away lattice for the hoist whose hoist rope is reeved on the swing-away lattice.

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• Confirm the entry.

H

The lifting capacity for the RCL code is enabled once the telescopic sections are locked.

s Operating instructions for lattice extension GMK4080-2

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5 - 109

Swing-away lattice 5.5 Operation with swing-away lattice

Shutdown

Operation with the swing-away lattice is monitored by the RCL. When operating with the swing-away lattice, RCL shutdowns may occur for Operating the same reasons as when operating with the main boom; instructions GMK4080-2.

à

In certain rigging modes, the RCL shuts down even when loads are lifted that are lighter than the maximum load bearing capacity specified in the lifting capacity table.

– During operation with the swing-away lattice If a hook block (3) is reeved on the main boom, then the displayed current load (1) is affected by: – The weight of the lifted load (2) and – The weight of the hook block (3)

– During main boom operation If a hook block (3) is reeved on the swing-away lattice, then the displayed current load (1) is affected by: – The weight of the lifted load (2), – The weight of the swing-away lattice (4) and – The weight of the hook block (3)

5.5.2

Derricking the main boom

Slewing range of 360°

G

Risk of accidents if the RCL is overridden Do not override the RCL when lowering into horizontal position.

If the RCL is overridden, crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The prerequisites for raising and lowering the main boom with a rigged swing-away lattice and a slewing range of 360° are monitored by the RCL. Further information on the permissible angle ranges and lifting capacities is provided in the lifting capacity table; Rigging tables – lattice extension.

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à

5 - 110

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.5 Operation with swing-away lattice

5.5.3

Telescoping with rigged swing-away lattice

Slewing range of 360°

S

Risk of overloading the main boom If you are telescoping the main boom with the swing-away lattice rigged, you must not simultaneously slew the superstructure.

This prevents the main boom from being overloaded by additional lateral forces and increased vibration.

The telescoping of the main boom with a swing-away lattice rigged (in the operating position) is monitored by the RCL. Telescoping is only unlocked at specific main boom and lattice extension angles when a maximum permissible load is not exceeded. Further information on the permissible angles and the maximum permissible load is provided in the lifting capacity tables. They also provide information on telescoping when rigging the swing-away lattice; à Rigging tables – lattice extension.

5.5.4

Derricking the swing-away lattice in operation

Switching on the derricking gear

When the ignition is switched on, all of the power units are switched off and the lamps in the corresponding buttons will light up only dimly.

• Press the button (1) once.

– The lamp in button (1) will light up brightly.

– Symbol (2) is green when the derricking gear is switched on.

If the control lever is assigned more than one function, all other power units which are assigned the same control lever movement are switched off.

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5 - 111

Swing-away lattice 5.5 Operation with swing-away lattice

Raising and lowering

G

You can adjust the sensitivity of the control levers to the operating conditions; Operating instructions GMK4080-2.

à

Risk of accident due to unexpected crane movements If the control lever is assigned more than one function, check that the control lever function for lattice extension derricking gear is switched on before you move the control lever to derrick the swing-away lattice.

This prevents accidents due to unexpected crane movements.

Lowering:

Push the control lever to the right – the swing-away lattice will be lowered.

Raising:

Push the control lever to the left – the swing-away lattice will be raised.

Other derricking settings are performed in the same manner, as described in the Operating instructions GMK4080-2.

– Changing the engine speed – Limiting the derricking speed – Operating hours display When derricking the swing-away lattice the RCL switches automatically to the values for fixed angle and intermediate angle stated in the lifting capacity table if permissible for the load currently being lifted.

If this switchover is not permitted for the load currently raised, derricking will be switched off and a corresponding error message will be generated.

Switching off the derricking gear

• Press the button (1) once.

– The lamp in the button (1) lights up dimly.

– Symbol (2) is red when the derricking gear is switched off.

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When the ignition is switched off, all power units are switched off and the lamps in the corresponding buttons are lit only dimly.

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.5 Operation with swing-away lattice

5.5.5

G

Procedure if permissible wind speed is exceeded Risk of accidents due to excessively high wind speeds If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

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

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

• Make sure that you observe the specifications for monitoring the wind speed;

à Lifting capacity table and Operating instructions GMK4080-2.

If the maximum permitted wind speed is exceeded Automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

• Put the truck crane into the rigging mode specified for the current wind

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speed in the lifting capacity table.

Operating instructions for lattice extension GMK4080-2

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5 - 113

Swing-away lattice 5.5 Operation with swing-away lattice

5.5.6

Information about the main boom operation when the swing-away lattice is folded/rigged

Folded When working with the main boom with the swing-away lattice folded, the loads specified in the lifting capacity table are reduced and displayed on the RCL display for Maximum load.

H Rigged

The lifting capacity tables contain operations planning information specifying the values that must be subtracted from the specified maximum lifting capacities for certain rigging modes; Remarks about working with the swing-away lattice.

à

Main boom operation with a swing-away lattice rigged (in the operating position) is permitted with swing-away lattice combinations A and B. You must enter an RCL code for the main boom without a swing-away lattice in order to operate in this mode. This operating mode is only permissible under certain specific rigging modes.

More information on the permissible rigging modes and the swing-away lattice lengths is provided in the lifting capacity tables; Remarks about working with the swing-away lattice.

à

The lifting capacities specified in the lifting capacity table are reduced for main boom operation with a rigged swing-away lattice. The lifting capacity tables contain operations planning information specifying the values that must be subtracted from the specified maximum lifting capacities for certain rigging modes; Remarks about working with the swing-away lattice.

à

The RCL display does not display the reduced values correctly.

This means that the displayed value might deviate from the value that was previously calculated during the operations planning.

G 5 - 114

Risk of accidents if the RCL is overridden Do not under any circumstances override the RCL. If the RCL is overridden, crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

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Operating instructions for lattice extension GMK4080-2

19.06.2019

If this is the case, the RCL is not faulty. Do not override the RCL. Even if the displayed value is higher than the calculated value.

Swing-away lattice 5.5 Operation with swing-away lattice

5.5.7

Instructions for turning loads over Turning loads over with a swing-away lattice is only permitted with combinations A or B; Turning loads over, p. 10 - 1.

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à

Operating instructions for lattice extension GMK4080-2

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5 - 115

Swing-away lattice 5.5 Operation with swing-away lattice

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Blank page

5 - 116

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.6 Maintenance

5.6

Maintenance

H 5.6.1

If the swing-away lattice has been in storage for an extended period of time, perform maintenance work on it before the next time it is used, at the very latest.

Maintenance plan W

W

Maintenance work on the LATTICE EXTENSION: weekly Swing-away lattice – Grease the piston rod of the derricking cylinder

5.6.2

Maintenance plan M 1

à p. 5 - 121

M1

Maintenance work on the LATTICE EXTENSION: monthly/after 100 oper. hrs Swing-away lattice

à p. 5 - 118

– Lubricate the pins

5.6.3

Maintenance plan M 3

M3

Maintenance work on the LATTICE EXTENSION: every three months/after 250 oper. hrs Swing-away lattice

à p. 5 - 120

19.06.2019

– Check the sheaves

Operating instructions for lattice extension GMK4080-2

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5 - 117

Swing-away lattice 5.6 Maintenance

5.6.4

M 12

Maintenance plan M 12

Maintenance work on the LATTICE EXTENSION: every 12 months/after 1,000 oper. hrs Swing-away lattice

à p. 5 - 122

– Lubricate joints

5.6.5

Description of maintenance work

Pins Grease 1) Grease 1)

Designation to DIN 51502

Specification classification

GROVE part no.1)

KP - 1K - 50

DIN 51825

03233369

à Maintenance manual

Prerequisite – The truck crane is secured against unauthorised use; manual.

à Maintenance

or

à p. 5 - 25.

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– The swing-away lattice is removed;

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.6 Maintenance

Lubricate the pins Lubricate the pins specified here.

– Four pins (3) on the connection between section 1 and section 2, left/right – Four pins (1) on the connection on the main boom, left and right.

– Two swivel pins (2).

– The pins (4) on the deflection sheaves.

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Swing-away lattice 5.6 Maintenance

Sheaves Grease 1) Grease 1)

Designation to DIN 51502

Specification classification

GROVE part no.1)

KP - 1K - 50

DIN 51825

03233369

à Maintenance manual

Check the sheaves Check all sheaves specified here for damage, wear, mobility and heavy soiling.

• Check sheaves (1) to (4).

• Have damaged, worn, stiff or extremely soiled sheaves replaced by Manitowoc Crane Care or by an authorised GROVE dealer or your repair

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crew.

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Operating instructions for lattice extension GMK4080-2

Swing-away lattice 5.6 Maintenance

Piston rod GROVE part no.1)

Designation Lubricant RHUS SW 2; 1 kg (grease to be applied with a brush)

03325215

or Berulub spray; 0.5 litres (to be sprayed on) 1)

S

01929824

à Maintenance manual

Risk of damage to the piston rod packing due to rust Ensure that the piston rod is always kept covered with a layer of grease.

This avoids the formation of rust which damages the piston rod packing when lowering the boom.

Perform this maintenance work weekly or at the following points in time: – After a longer period of storage – After removal – After every high-pressure cleaning of the truck crane – Before the next usage of the crane – Before putting out of service

• Clean any old grease, dirt particles and rust from the piston rod (1).

• Grease the piston rod, making sure it is evenly coated with a layer of grease.

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Swing-away lattice 5.6 Maintenance

Joints Grease 1) Grease 1)

Designation to DIN 51502

Specification classification

GROVE part no.1)

KP - 1K - 50

DIN 51825

03233369

à Maintenance manual

Prerequisite – The truck crane is secured against unauthorised use; manual.

à Maintenance

or – The swing-away lattice is removed;

à p. 5 - 25.

Lubricate joints Section 2 is fitted with two grease nipples (1).

• Clean the grease nipples (1).

• Press grease into the grease nipples (1) until

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new grease comes out at the lubricating point.

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Swing-away lattice 5.7 Finding and eliminating malfunctions

5.7

Finding and eliminating malfunctions

5.7.1

Troubleshooting table

Malfunction

Cause

Remedy

Lifting limit switch switches off (lamp (1) lights up)

Lifting limit switch not connected.

Connect the lifting limit switch; p. 5 - 94.

There is a second lifting limit switch connected to the main boom and it is not locked.

Lock the lifting limit switch; Operating instructions GMK4080-2.

One or more electrical connections are disconnected, according to the combination A or B.

Establish the electrical connection; p. 5 - 84.

The main boom cannot be telescoped when the swingaway lattice is rigged

The main boom is at an impermissible angle.

Derrick the main boom to the required angle; p. 5 - 110.

The swing-away lattice cannot be derricked

The lattice extension derricking gear is switched off.

Lattice extension derricking gear; p. 5 - 98.

The electrical connection between main boom head and section 2 is disconnected.

Establish the electrical p. 5 - 84. connection;

The hydraulic connection has been disconnected.

Establish the hydraulic p. 5 - 80. connection;

The RCL code entered is not valid for operation with the lattice extension.

Enter the RCL code for operation with the swingp. 5 - 109. away lattice;

The current load exceeds the derricking load – The Lower swing-away lattice movement is disabled. RCL error code 5 02 6 is displayed.

1. Raise the swing-away lattice.

à

à

à

à

à

à à

à

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

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5 - 123

Swing-away lattice 5.7 Finding and eliminating malfunctions

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.1 Notes on this chapter

6

Boom extension

6.1

Notes on this chapter

H

To assemble the boom extension, you require section 3 and the swing-away lattice (section 1 and section 2).

This chapter describes the installation and removal of section 3.

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For the installation and removal of section 1 and section 2, reference is made to the Swing-away lattice chapter where appropriate.

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6-1

Boom extension 6.1 Notes on this chapter

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6-2

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.2 Operations planning

6.2

Operations planning

6.2.1

Assembly

S

Risk of overturning in other combinations Assemble the boom extension only in the permissible combination specified in the lifting capacity table. Other combinations are not monitored by the RCL.

Permissible combination

Combination

Designation

Z + Y 1)

Sections used

A

Boom extension A

7.2 + 13.8 m (23.6 + 45.2 ft)

3+2+1

Designation in the lifting capacity table: Z = length before setting the angle Y = length after setting the angle

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1)

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6-3

Boom extension 6.2 Operations planning

6.2.2

Identification

Section 3

G

Risk of accidents when using an incorrect boom extension Install only the section 3 that belongs to the specific truck crane. Other parts must not be installed.

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The truck crane and the corresponding section 3 must be labelled with the same serial number (1).

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.2 Operations planning

6.2.3

Slinging points

Section 3

G

Risk of accidents if used improperly Sling section 3 to the slinging points provided. Use only lifting gear and joining elements of sufficient load bearing capacity.

Slinging point The slinging points (1) are marked with stickers (2).

Weight The sticker (3) gives the weight and the necessary lifting gear.

Guide rope

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The grille serves as the slinging point for the guide rope (4).

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6-5

Boom extension 6.2 Operations planning

6.2.4

Transport dimensions and weights

Section

3

Length x width x height in m (ft)

Weight in kg (lbs)

6.2 x 0.8 x 1.10 (20.5 x 2.7 x 3.7)

395 (860)

The following values apply for both the derricking and inclinable swingaway lattice.

6.2.5

Transport condition

Section 3

• Check that the lattice is secured in transport condition and secure it now if necessary.

– The deflection sheave (1) is folded in and secured.

– The section 3 must be secured to a suitable base plate support (2).

– The plug (3) has been inserted in the dummy socket.

– All pins (4) must be secured in the holders.

– In the version for the derricking swingaway lattice, all hoses (5) are stowed in section 3. The hoses are closed off with caps (7).

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– The electrical cable is closed with the cap (6).

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.3 Checklists for rigging work

6.3

Checklists for rigging work

6.3.1

Overview The following table shows which checklist is applicable for any required rigging work.

Required rigging work

Checklist

– Installing the boom extension

CHECKLIST: Installing the boom extension, p. 6 - 8

– Removing the boom extension

CHECKLIST: Removing the boom extension, p. 6 - 13

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Boom extension

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6-7

Boom extension 6.3 Checklists for rigging work

6.3.2

CHECKLIST: Installing the boom extension

H

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

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear; Operating instructions GMK4080-2.

à

– The appropriate counterweight for operation of the crane must be Operating instructions GMK4080-2. rigged;

à

– The main boom must be completely retracted and lowered into the Operating instructions GMK4080-2. horizontal position;

à

– The swing-away lattice is removed.

– An auxiliary crane must be available.

2. For a derricking swing-away lattice: – If necessary, mount the hose drum;

à p. 4 - 3.

– If necessary, check that the locking device has been released; p. 4 - 5.

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à

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.3 Checklists for rigging work

– If necessary, move the hoses into the position for working with the lattice extension; p. 4 - 6.

à

3. Check the transport condition of section 3;

à p. 6 - 6.

4. Fold out the deflection sheave on section 3;

à p. 6 - 19.

5. – Fasten slings to section 3 and attach a guide rope.

– Lift section 3 into position in front of the main boom.

à Identification, p. 6 - 4, à Slinging points, p. 6 - 5, à Transport dimensions and weights, p. 6 - 6.

6. – Establish the connection between section 3 and the main boom; p. 6 - 20.

à

– Remove the lifting gear and the guide rope.

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6-9

Boom extension 6.3 Checklists for rigging work

7. Establish the electrical connection between section 3 and the main boom; p. 6 - 22.

à

8. For a derricking swing-away lattice: – Establish the hydraulic connection between section 3 and the main p. 6 - 24. boom;

à

9. Check whether the swing-away lattice is secured for transport; p. 5 - 8.

à

10. Fold out the deflection sheave on section 2;

à p. 5 - 89.

11. Sling lifting gear to the swing-away lattice B and fasten a guide rope.

à Assembly, p. 6 - 3. à Slinging points, p. 5 - 4.

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12. Lift the swing-away lattice in front of section 3.

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.3 Checklists for rigging work

13. Establish a connection between section 3 and the swing-away lattice; p. 6 - 25.

à

14. Remove the lifting gear and the guide rope.

15. Establish the electrical connection between section 3 and the swingaway lattice; p. 6 - 27.

à

16. For a derricking swing-away lattice: – Establish the hydraulic connection between section 3 and the swingp. 6 - 29. away lattice;

à

17. Place the hoist rope on section 3;

18. For further rigging of the swing-away lattice, perform all the steps in the CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – in p. 5 - 42. the operating position starting from point 16.;

à

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H

à p. 6 - 30.

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6 - 11

Boom extension 6.3 Checklists for rigging work

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.3 Checklists for rigging work

6.3.3

CHECKLIST: Removing the boom extension

H

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

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear; Operating instructions GMK4080-2.

à

– The appropriate counterweight for operation of the crane must be rigged; Operating instructions GMK4080-2.

à

– The main boom must be completely retracted and lowered into the Operating instructions GMK4080-2. horizontal position;

à

– An auxiliary crane must be available.

H

Removal is started in the same manner as rigging of the swing-away lattice in transport position.

2. For rigging of the swing-away lattice, perform all the steps in the CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – p. 5 - 54. in the transport position up to and including point 17.;

à

3. Unreeve the hoist rope and remove it from section 3;

à p. 6 - 30.

If necessary, roll the hoist rope onto the drum up to the main boom head.

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s Operating instructions for lattice extension GMK4080-2

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6 - 13

Boom extension 6.3 Checklists for rigging work

4. Sling lifting gear to the swing-away lattice and fasten a guide rope.

à Transport dimensions and weights, p. 5 - 7, à Slinging points, p. 5 - 4

5. Disconnect the electrical connection between section 3 and the swingaway lattice; p. 6 - 27.

à

6. For a derricking swing-away lattice: – Disconnect the hydraulic connection between section 3 and the p. 6 - 29. swing-away lattice;

à

7. Disconnect the connection between section 3 and the swing-away lattice; p. 6 - 25.

à

8. Lift the swing-away lattice off section 3 and set it down.

à Slinging points, p. 5 - 4.

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9. Remove the lifting gear and the guide rope.

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.3 Checklists for rigging work

10. For a derricking swing-away lattice: – Detach the hand-held control;

à Operating instructions GMK4080-2.

11. Fold the deflection sheave onto section 2;

à p. 5 - 89.

12. Check whether the swing-away lattice is secured for transport; p. 5 - 8.

à

13. Disconnect the electrical connection between section 3 and the main p. 6 - 22. boom;

à

14. For a derricking swing-away lattice: – Disconnect the hydraulic connection between section 3 and the main p. 6 - 24. boom;

à

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15. Fasten slings to section 3 and attach a guide rope:

à Identification, p. 6 - 4, à Slinging points, p. 6 - 5. à Transport dimensions and weights, p. 6 - 6,

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s 6 - 15

Boom extension 6.3 Checklists for rigging work

16. Disconnect the connection between section 3 and the main boom; p. 6 - 20.

à

17. Remove section 3 from the main boom and put it aside.

18. Fold the deflection sheave onto section 3;

à p. 6 - 19.

19. Check the transport condition of section 3;

à p. 6 - 6.

20. Reeve the hoist rope on the main boom head, or roll it onto the drum; Operating instructions GMK4080-2.

à

21. If necessary, move the hoses into the position for main boom p. 4 - 6. operation; 19.06.2019

à

6 - 16

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.3 Checklists for rigging work

à p. 4 - 3.

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22. If necessary, remove the hose drum;

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6 - 17

Boom extension 6.3 Checklists for rigging work

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.4 Description of the rigging work

6.4

Description of the rigging work

6.4.1

Section 3 – Folding out/folding in the deflection sheave

G

Risk of crushing Always hold the deflection sheave firmly by the handle when removing the pin.

Your fingers may be crushed if you hold the sheave by the side panel.

Folding out

• (A) – Hold the deflection sheave (2) by the handle (1).

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

• (B) – Fold the deflection sheave (2) upwards until the connecting points line up.

• Insert the pins (3) into the connecting points.

• Secure the pins.

Folding in

• (A) – Hold the deflection sheave (2) by the handle (1).

• Remove the pins (3) from the connecting points.

• (B) – Fold the deflection sheave (2) downwards until the connecting points line up.

• Insert the pins (3) into the connecting points.

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• Secure the pins.

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6 - 19

Boom extension 6.4 Description of the rigging work

6.4.2

G S

Section 3/main boom – Establish/disconnect the connection Risk of accidents due to swinging sections Always secure the sections with a guide rope from the ground before establishing or disconnecting connections.

This prevents you from being crushed or caught by swinging sections.

Risk of damage to connecting cables and hydraulic hoses Before dismantling, ensure that the electric and hydraulic connections have been disconnected.

This prevents damage to the connecting cables and hydraulic hoses during removal.

– Section 3 has been slung to an auxiliary crane; – A guide rope must be attached.

à p. 6 - 5.

Connecting

• Align the connecting points (2).

• Remove the pins (1) from the holders (3) and insert them into the connecting points (2).

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• Secure the pins.

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.4 Description of the rigging work

Disconnecting

• Remove the pins (1) from the connecting points (2) and insert them into the holders (3).

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• Secure the pins.

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6 - 21

Boom extension 6.4 Description of the rigging work

6.4.3

Section 3/main boom – Establish/disconnect the electrical connections Establishing the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket (5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Connecting the camera

• Unwind the cable (3) from the holder (4).

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

• Lay the cable (3) so that it will not be

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damaged during crane operation.

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.4 Description of the rigging work

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and place it in the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

Disconnecting the camera

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

• Wind the cable (3) onto the holder (4).

• Close the plug (2) and the socket (1) with

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caps.

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6 - 23

Boom extension 6.4 Description of the rigging work

6.4.4

Section 3/main boom – Establish/disconnect the hydraulic connection Connecting

• If necessary, bring the connections (2) on the right side of the main boom head into the position Working with the lattice extension, p. 4 - 6.

• Guide the hose lines (1) to the right out of section 3 and up to the main boom head.

• Remove the caps.

• Connect the hoses (1) to the connections (2).

Disconnecting

• Disconnect the hoses (1) from the connections (2).

• Close off the hoses and connections with the caps.

• Stow the hoses (1) securely in section 3.

• If necessary, bring the connections (2) into

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the position Main boom operation, p. 4 - 7.

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.4 Description of the rigging work

6.4.5

G S

Section 3/swing-away lattice – Establish/disconnect the connection Risk of accidents due to swinging sections Always secure the sections with a guide rope from the ground before establishing or disconnecting connections.

This prevents you from being crushed or caught by swinging sections.

Risk of damage to connecting cables and hydraulic hoses Before dismantling, ensure that the electric and hydraulic connections have been disconnected.

This prevents damage to the connecting cables and hydraulic hoses during removal.

– The swing-away lattice must be slung to an auxiliary crane.

– A guide rope must be attached.

Connecting

• Lift the swing-away lattice in front of the main boom head in such a way that the connecting points (2) align on both sides.

On both sides:

• Remove the pins (1) from the holders (3).

• Insert the pins (1) into the connecting points (2).

• Secure the pins.

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6 - 25

Boom extension 6.4 Description of the rigging work

Disconnecting On both sides:

• Remove the pins (1) from the connecting points (2).

• Insert the pins into the holders (3).

• Secure the pins.

• Set down the swing-away lattice and check

à

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the transport condition; Transport condition – removed, p. 5 - 8.

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.4 Description of the rigging work

6.4.6

Section 3/swing-away lattice – Establish/disconnect the electrical connections Establishing the electrical connections

• Unwind the cable (3) from the holder (4).

• Remove the plug (2) from the dummy socket (5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Connecting the camera

• Unwind the cable (3) from the holder (4).

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

• Lay the cable (3) so that it will not be damaged during crane operation.

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6 - 27

Boom extension 6.4 Description of the rigging work

Disconnecting the electrical connections

• Remove the plug (2) from the socket (1) and place it in the dummy socket (5).

• Wind the cable (3) onto the holder (4).

• Cover the socket (1) with the cap.

Disconnecting the camera

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

• Wind the cable (3) onto the holder (4).

• Close the plug (2) and the socket (1) with

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caps.

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.4 Description of the rigging work

6.4.7

Section 3/swing-away lattice – Establish/disconnect the hydraulic connection Connecting

• Feed the hoses (1) on the right hand side, past the swing-away lattice, to section 3.

• Remove the caps.

• Connect the hoses (1) to the connections (2).

• Lay the hoses through the holder (3) so they do not sag.

Disconnecting

• Disconnect the hoses (1) from the connections (2).

• Close off the hoses and connections with the caps.

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• Firmly insert the hoses (1) in the holder (3).

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6 - 29

Boom extension 6.4 Description of the rigging work

6.4.8

G

Section 3 – Fitting/removing the hoist rope Risk of accidents due to falling parts Always secure the sheaves and rods with retaining pins.

This prevents parts coming loose, falling out and causing injuries.

Fitting

• Remove the rod and sheave (2).

• Guide the hoist rope over the deflection sheave (1) and up to section 2.

• Install the sheave (2) and the rod.

• Secure the rod.

Removing

• Remove the rod and sheave (2).

• Remove the hoist rope from the deflection sheave (1) and set it down on the ground or reel it in up to the main boom head or up to the rope drum.

• Install the sheave (2) and the rod.

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• Secure the rod.

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.5 Operation with boom extension

6.5

Operation with boom extension

G

Risk of accidents due to overloading Crane operation with the main boom is prohibited when a boom extension is rigged.

Lifting a load with two hooks is prohibited when a boom extension is rigged.

The raising, lowering, slewing and derricking movements and telescoping of the main boom are carried out in the same way as for operation with the main boom. This section only contains information that you will need additionally for a rigged boom extension.

6.5.1

Setting the RCL

Input

• On the RCL, enter the current rigging mode for operation with a rigged boom extension. Do so either using the corresponding RCL code in accordance with the lifting capacity table (1) or via individual components (2).

When you input the current rigging mode via the individual components, you must also input: – the length before the angle (1) and – the length after the angle (2). and for the inclinable boom extension: – the set angle of the lattice extension (3).

• On the RCL, enter the current reeving on the boom extension for the hoist whose hoist rope is reeved on the boom extension.

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6 - 31

Boom extension 6.5 Operation with boom extension

• Confirm the entry.

H Shutdown

The lifting capacity for the RCL code is enabled once the telescopic sections are locked.

Operation with the boom extension is monitored by the RCL. When operating with the boom extension, RCL shutdowns may occur for the same reasons as when operating with the main boom; Operating instructions GMK4080-2.

à

In certain rigging modes, the RCL shuts down even when loads are lifted that are lighter than the maximum load bearing capacity specified in the lifting capacity table.

– During operation with the boom extension: If a hook block (3) is reeved on the main boom, then the displayed current load (1) is affected by: – The weight of the lifted load (2) and – The weight of the hook block (3)

6.5.2

Derricking, telescoping the main boom

Slewing range of 360°

G

Risk of accidents if the RCL is overridden Do not override the RCL when lowering into horizontal position.

If the RCL is overridden, crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The prerequisites for raising, lowering and telescoping of the main boom with a rigged boom extension and a slewing range of 360° are monitored by the RCL. Further information on the permissible angle ranges and lifting capacities is provided in the lifting capacity table; Rigging tables – lattice extension.

If the main boom is set to a steep angle and the boom extension is set to 0°, the hook block may hit the main boom.

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à

Boom extension 6.5 Operation with boom extension

6.5.3

G

Procedure if permissible wind speeds are exceeded Risk of accidents due to excessively high wind speeds If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

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

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

• Make sure that you observe the specifications for monitoring the wind

à

speed; Lifting capacity table and operating instructions Operating instructions GMK4080-2.

If the maximum permitted wind speed is exceeded Automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

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

6.5.4

Instructions for turning loads over

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Turning loads over with a rigged boom extension is prohibited.

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Boom extension 6.5 Operation with boom extension

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Operating instructions for lattice extension GMK4080-2

Boom extension 6.6 Maintenance

6.6

Maintenance

H 6.6.1

If the boom extension has been in storage for an extended period of time, perform maintenance work on it before the next time it is used, at the very latest.

Maintenance plan M 1

M1

Maintenance work on the BOOM EXTENSION: monthly/after approx. 100 oper. hrs Boom extension

à p. 6 - 36

– Lubricate the pins

6.6.2

Maintenance plan M 3

M3

Maintenance work on the BOOM EXTENSION: every three months/after 250 oper. hrs Boom extension

à p. 6 - 36

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– Check the sheaves

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6 - 35

Boom extension 6.6 Maintenance

6.6.3

Description of maintenance work Grease 1) Grease 1)

Designation to DIN 51502

Specification classification

GROVE part no.1)

KP - 1K - 50

DIN 51825

03233369

à Maintenance manual Lubricate the pins

• Grease the pins (1).

Check the sheaves

• Check the deflection sheave (2) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled sheaves replaced by Manitowoc Crane Care or by an authorised GROVE dealer or

19.06.2019

your repair crew.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.1 Operations planning

7

Heavy load lattice extension, 2.0 m (6.6 ft)

7.1

Operations planning

7.1.1

Assembly Permissible combinations

Designation

Y

Sections used

A

Heavy load lattice extension 2.0 m (6.6 ft)

2.0 m (6.6 ft)

5

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Combination

Operating instructions for lattice extension GMK4080-2

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7-1

Heavy load lattice extension, 2.0 m (6.6 ft) 7.1 Operations planning

7.1.2

G

Identification Risk of accidents if heavy load lattice extensions are interchanged!

Install only the heavy load lattice extension that belongs to the truck crane.

No other heavy load lattice extensions may be installed.

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The truck crane and the corresponding section 5 must be labelled with the same serial number (1).

7-2

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.1 Operations planning

7.1.3

G

Slinging points Risk of accidents if used improperly!

Sling the heavy load lattice extension only at the slinging points provided.

Use only lifting gear and joining elements of sufficient load bearing capacity.

Slinging point The slinging points (1) are marked with stickers (2).

Weight The sticker (3) gives data on the weight and the necessary lifting gear.

Guide rope A guide rope is fastened to the rope attachment point (4); Folding the rope attachment point in/out, p. 7 - 32.

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à

Operating instructions for lattice extension GMK4080-2

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7-3

Heavy load lattice extension, 2.0 m (6.6 ft) 7.1 Operations planning

Transport dimensions and weights

Section

Version

5

–

Length x width x height in m (ft)

Weight in kg (lbs)

2.30 x 0.90 x 1.40 (7.55 x 2.95 x 4.60)

330 (728)

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7.1.4

7-4

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.1 Operations planning

7.1.5

Transport condition

Removed

• Check that the heavy lattice load extension is in the transport condition or establish this now, if necessary.

– The pins (1) are secured in the holders.

– The socket (2) is closed with a cap and cable is wound onto the holder (3).

– The pins (4) are secured in the connecting points.

– The rope attachment point (5) is folded in; p. 7 - 32.

à

– The lifting limit switch (6) is removed.

– The 0° angle position must be set and the pin (7) must be inserted and secured.

– Section 5 must be secured to a suitable support.

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Operating instructions for lattice extension GMK4080-2

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7-5

Heavy load lattice extension, 2.0 m (6.6 ft) 7.1 Operations planning

Folded

• Check that the heavy lattice load extension is in the transport condition or establish this now, if necessary.

– The pins (1) are secured in the holders.

– The socket (2) is closed with a cap and cable is wound onto the holder (3).

– The pins (4) are secured in the connecting points.

– The rope attachment point (5) is folded in; p. 7 - 32.

à

– The lifting limit switch (6) is removed from the holder.

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– The 0° angle position must be set and the pin (7) must be inserted and secured.

7-6

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

7.2

Checklists for rigging work

7.2.1

Overview The distinction is made between various different procedures.

– Installation and removal These procedures have to be performed when the lattice extension is being transported separately. The installation and removal of the lattice extension is described.

– Rigging These procedures must be performed when the lattice extension is being transported on the crane. The changeover between the transport position and the operating position is described.

The table shows which checklist is applicable to any required rigging work.

Required rigging work – Heavy load lattice extension Install

– Heavy load lattice extension Remove

– In working position

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) installation into the working position, p. 7 - 8

– In transport position

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) Installation into the transport position, p. 7 - 11

– From operating position

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) removal from the working position, p. 7 - 13

– From transport position

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) removal from the transport position, p. 7 - 16

– In working position

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) rigging into the working position, p. 7 - 18

– In transport position

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) rigging into the transport position, p. 7 - 21

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– Heavy load lattice extension Rigging

checklist

Operating instructions for lattice extension GMK4080-2

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7-7

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

7.2.2

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) installation into the working position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– An auxiliary crane must be available.

2. Check the transport condition of section 5;

à p. 7 - 5.

3. – Fasten slings to section 5 and attach a guide rope.

– Lift section 5 into position in front of the main boom.

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à Identification, p. 7 - 2 à Transport dimensions and weights, p. 7 - 4 à Slinging points, p. 7 - 3

7-8

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

4. – Establish a mechanical connection between section 5 and the main boom; p. 7 - 25.

à

– Remove the lifting gear and the guide rope.

5. Adjust the angle position if necessary;

à p. 7 - 33.

6. Position the hoist cable on section 5 and reeve the hook block.

Section 5 –Fitting/removing the hoist rope, p. 7 - 37 Possible reeving methods on the heavy load lattice extension, p. 7 - 38

à à

à p. 7 - 39.

– Attach the lifting limit switch weight; à Operating instructions

7. – Install the lifting limit switch;

GMK4080-2.

8. If necessary, install the anemometer and air traffic control light; p. 7 - 41.

à

9. If necessary, mount the camera;

à p. 7 - 42.

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s Operating instructions for lattice extension GMK4080-2

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7-9

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

10. Check the horizontal alignment of the truck crane and correct it if necessary; Operating instructions GMK4080-2.

à

à p. 7 - 45.

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11. Enter and confirm the current rigging mode;

7 - 10

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

7.2.3

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) Installation into the transport position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– An auxiliary crane must be available.

2. Check the transport condition of section 5;

à p. 7 - 5.

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Operating instructions for lattice extension GMK4080-2

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7 - 11

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

3. – Fasten slings to section 5 and attach a guide rope.

– Lift section 5 into position at the main boom.

à Identification, p. 7 - 2 à Transport dimensions and weights, p. 7 - 4 à Slinging points, p. 7 - 3

4. Establish a mechanical connection between section 5 and the main p. 7 - 26. boom;

à

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5. Remove the lifting gear and the guide rope.

7 - 12

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

7.2.4

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) removal from the working position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– An auxiliary crane must be available.

2. If necessary, remove the anemometer and air traffic control light; p. 7 - 41.

à

3. If necessary, remove the camera;

à p. 7 - 42.

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Operating instructions for lattice extension GMK4080-2

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7 - 13

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

4. – Remove the lifting limit switch weight; GMK4080-2 – Remove the lifting limit switch;

à Operating instructions

à p. 7 - 40.

5. Set down the hook block, unreeve the hoist rope and remove it from section 5 if necessary; p. 7 - 37.

à

6. Adjust to a 0° angle, if necessary;

à p. 7 - 33.

7. Reeve the hoist rope onto the main boom head, or roll it on to the drum; Operating instructions GMK4080-2.

à

8. Fasten slings to section 5 and attach a guide rope.

à Identification, p. 7 - 2 à Transport dimensions and weights, p. 7 - 4 à Slinging points, p. 7 - 3

9. Disconnect the connection between section 5 and the main boom; p. 7 - 26.

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à

7 - 14

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

10. Lift section 5 off the main boom and put it aside.

11. Remove the lifting gear and the guide rope.

à p. 7 - 5.

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12. Check the transport condition of section 5;

Operating instructions for lattice extension GMK4080-2

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7 - 15

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

7.2.5

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) removal from the transport position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– Section 5 is folded up against the side of the main boom;

à p. 7 - 6.

– An auxiliary crane must be available.

2. Fasten slings to section 5 and attach a guide rope.

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à Identification, p. 7 - 2 à Transport dimensions and weights, p. 7 - 4 à Slinging points, p. 7 - 3

7 - 16

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

3. Disconnect the connection between section 5 and the main boom; p. 7 - 26.

à

4. Lift section 5 off the main boom and put it aside.

5. Remove the lifting gear and the guide rope.

à p. 7 - 5.

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6. Check the transport condition of section 5;

Operating instructions for lattice extension GMK4080-2

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7 - 17

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

7.2.6

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) rigging into the working position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– Section 5 is folded up against the side of the main boom;

2. Fasten the guide rope to section 5;

à p. 7 - 6.

à p. 7 - 3.

3. – Move section 5 into the working position;

à p. 7 - 28.

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– Remove the guide rope.

7 - 18

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

4. Adjust the angle position if necessary;

à p. 7 - 33.

5. Position the hoist cable on section 5 and reeve the hook block.

Section 5 –Fitting/removing the hoist rope, p. 7 - 37 Possible reeving methods on the heavy load lattice extension, p. 7 - 38

à à

à p. 7 - 39.

– Attach the lifting limit switch weight; à Operating instructions

6. – Install the lifting limit switch;

GMK4080-2.

7. If necessary, install the anemometer and air traffic control light; p. 7 - 41.

à

8. If necessary, mount the camera;

à p. 7 - 42.

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Operating instructions for lattice extension GMK4080-2

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7 - 19

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

9. Check the horizontal alignment of the truck crane and correct it if necessary; Operating instructions GMK4080-2.

à

à p. 7 - 45.

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10. Enter and confirm the current rigging mode;

7 - 20

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

7.2.7

CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) rigging into the transport position

H

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

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V; p. 5 - 59.

à

– The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

2. If necessary, remove the anemometer and air traffic control light; p. 7 - 41.

à

3. If necessary, remove the camera;

à p. 7 - 42.

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Operating instructions for lattice extension GMK4080-2

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7 - 21

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

4. – Remove the lifting limit switch weight; GMK4080-2 – Remove the lifting limit switch;

à Operating instructions

à p. 7 - 40.

5. Set down the hook block, unreeve the hoist rope and remove it from section 5 if necessary; p. 7 - 37.

à

6. Adjust to a 0° angle, if necessary;

à p. 7 - 33.

7. Reeve the hoist rope onto the main boom head, or roll it on to the drum; Operating instructions GMK4080-2.

à

à p. 7 - 3.

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8. Fasten the guide rope to section 5;

7 - 22

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

9. Move section 5 into the transport position;

à p. 7 - 30.

10. Remove the lifting gear and the guide rope.

à p. 7 - 6.

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11. Check the transport position of section 5;

Operating instructions for lattice extension GMK4080-2

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7 - 23

Heavy load lattice extension, 2.0 m (6.6 ft) 7.2 Checklists for rigging work

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Blank page

7 - 24

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3

Description of the rigging work

7.3.1

Section 5/main boom– Establish/separate the connection in the working position

G

Risk of accidents due to swinging parts!

Always secure the sections with a guide rope from the ground before establishing or separating connections.

This prevents you from being crushed or caught by swinging sections.

– Section 5 must be attached to an auxiliary crane.

– A guide rope must be attached.

Connecting

• Align the connecting points (1).

• Remove the pins (2) from the holders (3) and insert them into the connecting points (1) at both sides.

• Secure the pins.

Disconnecting

• Remove the pins (2) from the connecting points (1) and insert them into the clamps (3) at both sides.

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• Secure the pins.

Operating instructions for lattice extension GMK4080-2

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7 - 25

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.2

G

Section 5/main boom – Establish/separate the connection in the transport position Risk of accidents due to swinging parts!

Always secure the sections with a guide rope from the ground before establishing or separating connections.

This prevents you from being crushed or caught by swinging sections.

– Section 5 must be attached to an auxiliary crane.

– A guide rope must be attached.

Connecting

• Remove the pins (1) and (3) from the connecting points (2) and (4).

• Lift section 5 onto the side of the main boom.

• Align the connecting point (4) on section 5 and the holder(5).

• Fit the pin (3) into the connecting point (4) and secure it.

• Swing section 5 so that the connecting point (2) is aligned.

• Fit the pin (1) into the connecting point (2)

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and secure it.

7 - 26

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

Disconnecting

• Remove the pins (1) and (3) from the connecting points (2) and (4).

• Lift section 5 from the main boom and put it aside.

• Fit the pin (1) into the connecting point (2) and secure it.

• Fit the pin (3) into the connecting point (4)

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and secure it.

Operating instructions for lattice extension GMK4080-2

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7 - 27

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.3

Bringing section 5 from the transport position into the working position – A guide rope must be attached.

• Remove the pin (1) from the connecting point (2).

• Swing the heavy load lattice extension to the main boom head until the connecting points (7) are aligned.

G

Risk of accidents due to the heavy load lattice extension falling down!

Always first establish a connection to the main boom head before separating the connection to the basic section.

This way, you can avoid the heavy load lattice extension having no connection with the main boom and falling down.

• Remove the pins (6) from the clamps (5).

• Insert the pins (6) into the connecting points (7) and secure them.

• Fit the pin (1) into the connecting point (2) and secure it.

• Remove the pin (3) from the connecting

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point (4).

7 - 28

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

• Swing the heavy load lattice extension in front of the main boom head until the connecting points (1) are aligned.

• Remove the pins (2) from the clamps (5).

• Insert the pins (2) into the connecting points (1) and secure them.

• Fit the pin (3) into the connecting point (4)

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and secure it.

Operating instructions for lattice extension GMK4080-2

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7 - 29

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.4

Bringing section 5 from the working position into the transport position – A guide rope must be attached.

• Remove the pins (2) from the connecting points (1).

• Insert the pins (2) into the clamps (5) and secure them.

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

S

Risk of damage to the driver's cab Make sure that a 0° angle position is set before swinging the heavy load lattice extension onto the main boom. This prevents damage to the driver's cab.

• Swing the heavy load lattice extension onto the main boom until the

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connecting point (4) is aligned.

7 - 30

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

G

Risk of accidents due to the heavy load lattice extension falling down!

Always first establish a connection to the basic section before separating the connection to the main boom head.

This way, you can avoid the heavy load lattice extension having no connection with the main boom and falling down.

• Fit the pin (3) into the connecting point (4) and secure it.

• Remove the pin (1) from the connecting point (2).

• Remove the pins (6) from the connecting points (7).

• Insert the pins (6) into the clamps (5) and secure them.

• (A) – Swing the heavy load lattice extension onto the main boom until the connecting point (2) is aligned.

• (B) – Fit and secure the pin (1) in the connect-

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ing point (2).

Operating instructions for lattice extension GMK4080-2

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7 - 31

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.5

S

Folding the rope attachment point in/out Risk of damage when the rope attachment point is folded out!

Always fold the rope attachment point in for transport and for operation with an odd number of lines. This prevents the rope attachment point from being damaged or the rope attachment point and hoist rope from being damaged during operation.

Folding out

• (A) – Hold the rope attachment point (2) tight and remove the retaining pin (1).

• (B) – Fold the rope attachment point downwards.

• Fasten the retaining pin (1) to the clamp.

Folding in

• (A) – Remove the retaining pin (1).

• (B) – Fold the rope attachment point (2) to the rear.

• Secure the rope attachment point – fasten

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the retaining pin (1) to the clamp.

7 - 32

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.6

G

Section 5 – Setting the angle – with the hoist rope Danger of uncontrolled movements!

Always secure the angle piece with the hoist rope before removing any pins. This prevents the heavy load lattice extension from folding down in an uncontrolled manner.

Fastening the hoist rope

• Unreel the hoist rope up to the heavy load lattice extension.

• Remove the rod (3).

• Fold the rope attachment point (2) upwards.

• Fasten the padlock (1) to the rope attachment point (2).

• Secure the rod (3) in the connecting points.

S

Risk of damage!

Raise and lower the heavy load lattice extension only slowly and carefully using the hoist and do not pull the heavy load lattice extension against the end stop. This prevents damage to the rope sheaves, hoist rope or parts of the heavy load lattice extension.

– Adjusting to a 0° angle

• (A) – Use the hoist to lift the heavy load lattice extension until the load is relieved from the pin (1).

• Remove the pin (1) from the connecting point (2).

• (B) – Use the hoist to lift the heavy load lattice extension all the way to the end stop.

• Fit the pin (1) into the connecting point (3) and secure it.

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s Operating instructions for lattice extension GMK4080-2

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7 - 33

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

– Adjusting to a 40° angle

• (A) – Use the hoist to lift the heavy load lattice extension until the load is relieved from the pin (1).

• Remove the pin (1) from the connecting point (3).

• (B) – Use the hoist to lower the heavy load lattice extension all the way to the end stop.

• Fit the pin (1) into the connecting point (2) and secure it.

Removing the hoist rope

• Relieve the load on the padlock (1) back and remove it from the rope attachment point (2).

• Remove the rod (3).

• Fold the rope attachment point downwards.

When rigging in the transport position

• Remove the hoist rope from the sheave (2) and secure the rod (1).

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• Secure the rod (3) in the connecting points.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.7

Section 5 – Setting the angle – with a chain hoist The angle can also be set using the hoist rope;

G

à p. 7 - 33.

Danger of uncontrolled movements!

Always secure the angle piece with the hoist rope before removing any pins. This prevents the heavy load lattice extension from folding down in an uncontrolled manner.

Attaching the chain hoist

• Attach the chain hoist (3) at the slinging points (1) and (2).

– Adjusting to a 0° angle

• (A) – Use the chain hoist to lift the heavy load lattice extension until the load is relieved from the pin (1).

• Remove the pin (1) from the connecting point (2).

• (B) – Use the chain hoist to lift the heavy load lattice extension all the way to the end stop.

• Fit the pin (1) into the connecting point (3) and secure it.

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7 - 35

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

– Adjusting to a 40° angle

• (A) – Use the chain hoist to lift the heavy load lattice extension until the load is relieved from the pin (1).

• Remove the pin (1) from the connecting point (3).

• (B) – Use the chain hoist to lower the heavy load lattice extension all the way to the end stop.

• Fit the pin (1) into the connecting point (2) and secure it.

S

Risk of damage during crane operation!

Always remove the chain hoist before starting crane operation.

This prevents overloading of the chain hoist and prevents damage resulting from a collision between chain hoist components and the crane.

Removing the chain hoist The 0° or 27° angle has been set.

• Unload the chain hoist (3).

• Remove the chain hoist from the slinging

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points (1) and (2).

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.8

Section 5 –Fitting/removing the hoist rope

G

Risk of accidents due to falling parts!

Always secure the sheaves and rods with retaining pins.

This prevents sections coming loose, falling out and causing injuries.

Fitting

• Remove the rods (1).

• For operating with an even number of lines – fold out the rope attachment point (4); p. 7 - 32.

à

• Guide the hoist rope over the sheaves (2) and (3).

• Insert the rods (1).

• Secure the rods.

Removing

H

If the angle position needs to be set during further rigging, then remove the hoist rope only from the sheave (3).

Removing

• Remove the rods (1).

• Remove the hoist rope from the sheaves (2) and (3).

• Fold the rope attachment point (4) in;

à p. 7 - 32.

• Insert the rods (2).

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• Secure the rods.

Operating instructions for lattice extension GMK4080-2

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7 - 37

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.9

Possible reeving methods on the heavy load lattice extension For straight reeving, the hoist rope is attached to the rope attachment point (1). Fold out the rope attachment point; p. 7 - 32.

à

Reeve the hoist rope;

à Operating instructions GMK4080-2.

1 sheave hook block Reeving A

2-fall

B

1-fall

Hook tackle Reeving 1-fall

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C

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.10

Installing/removing the lifting limit switch

Installation

If only a single lifting limit switch is available you must use the lifting limit switch belonging to the main boom; Operating instructions GMK4080-2.

à

If several lifting limit switches are available, all those lifting limit switches on the main boom from which no lifting limit switch weight is suspended must be overridden; Operating instructions GMK4080-2.

à

• Unwind the cable (3) from the clamp (4).

• Insert the plug (2) in the socket (1).

• Lay the cable so that it will not be damaged during crane operation.

• Plug the lifting limit switch (4) into the clamp (3).

• Secure the lifting limit switch.

• Fasten the cable so that it does not sag during crane operation and cannot be damaged.

• Insert the plug (2) in the socket (1).

• Install the lifting limit switch weight (5) and lay it around the hoist rope;

à Operating instructions GMK4080-2.

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7 - 39

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

Removing

• Pull the plug (2) out of the socket (1) and close it with the cap.

• Wind the cable (3) on to the clamp (4).

• Cover the socket (1) with the cap.

• Remove the lifting limit switch weight (5);

à Operating instructions GMK4080-2

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

• Cover the socket (1) with the cap.

• Remove the lifting limit switch (4) from the clamp (3).

• Stow the lifting limit switch so that it is safe in traffic, or install it on the main boom; Operating instructions GMK4080-2.

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à

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.11

S

Installing / removing the anemometer and air traffic control light Risk of damage during on-road driving and operating in halls!

Always remove the anemometer and air traffic control light before on-road driving and operating in halls.

This prevents the specified overall height from being exceeded at on-road level, and the anemometer from being damaged due to unfavourable air currents or collision with the hall ceiling.

Installing and removing You must install the anemometer on the main boom for operation with the heavy load lattice extension.

You must remove the anemometer for transportation and operation in a hall.

Installation and removal are performed in the same way as for main boom operation; Operating instructions GMK4080-2.

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à

Operating instructions for lattice extension GMK4080-2

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7 - 41

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

7.3.12

Installing/removing the camera For crane operation you must install the camera and switch it on.

For on-road driving, you must switch the camera off and remove it.

Operating the camera;

à Operating instructions GMK4080-2.

Installation

• Insert the camera (2) into the clamp (1) and secure it.

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

• Lay the cable (5) so that it will not be damaged during crane operation.

• Remove the cable (3) from the clamp (4).

• Insert the plug (2) in the socket (1).

• Lay the cable (3) so that it will not be

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damaged during crane operation.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

Removing

• Take the plug (3) out of the socket (4) and close the socket with the cap.

• Remove the camera (2) from the clamp (1) and insert the retaining pin in the clamp.

• Stow away the camera so that it will not be damaged during crane operation.

• Take the plug (2) out of the socket (1) and close the socket with the cap.

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• Fasten the cable (3) on the clamp (4).

Operating instructions for lattice extension GMK4080-2

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7 - 43

Heavy load lattice extension, 2.0 m (6.6 ft) 7.3 Description of the rigging work

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Blank page

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.4 Operating the heavy load lattice extension

7.4

Operating the heavy load lattice extension The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will need for a rigged or folded heavy load lattice extension.

7.4.1

Setting the RCL

Input

• You can enter the current rigging mode with the heavy load lattice extension via the RCL code or via the individual components.

– Via the RCL code

• Select the RCL code (1) corresponding to the current rigging mode on the display (2) according to the lifting capacity table.

– Via individual components

• Select and conform the slewing range, outrigger span, and counterweight for the current rigging mode.

• Select the symbol (1) heavy load lattice extension for the boom system.

• Select and confirm the current rigging mode.

2 The length of the heavy load lattice extension 3 The angle of the heavy load lattice extension 4 The current reeving on the heavy load lattice extension for the hoisting gear whose hoist rope is reeved on the heavy load lattice extension

• Confirm the entry with the symbol (5).

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7 - 45

Heavy load lattice extension, 2.0 m (6.6 ft) 7.4 Operating the heavy load lattice extension

shutdown

Operation with the heavy load lattice extension is monitored by the RCL. When operating with the heavy load lattice extension, RCL shutdowns may occur for the same reasons as when operating with the main boom; Operating instructions GMK4080-2.

à

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table.

– During operation with the heavy load lattice extension If a hook block (3) is reeved at the main boom, then the displayed current load (1) is influenced by – the weight of the lifted load (2) and – the weight of the hook block (3).

– During main boom operation If a heavy load lattice extension (4) is installed, then the displayed current load (1) takes the following into consideration: – the weight of the lifted load (2) and – the weight of the heavy load lattice extension (4) and – the weight of the hook block (3) at the heavy load lattice extension.

à

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H

The lifting capacity tables contain information for operations planning specifying the values which must be subtracted from the specified maximum load bearing capacities for certain rigging modes; Remarks about working with the heavy load lattice extension.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.4 Operating the heavy load lattice extension

7.4.2

Derricking, telescoping the main boom

Slewing range of 360°

G

Risk of accidents if the RCL is overridden!

Do not override the RCL when lowering the boom into horizontal position.

If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The requirements that must be satisfied before raising, lowering and telescoping the main boom with a rigged heavy load lattice extension that are permitted for a slewing range of 360° are monitored by the RCL; Operating instructions GMK4080-2.

à

Note that the hook block or load can hit the heavy load lattice extension or the main boom when using large boom angles, 0° angle position and short slings.

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The RCL switches off the raising of the boom when the minimum permitted working radius has been reached.

Operating instructions for lattice extension GMK4080-2

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7 - 47

Heavy load lattice extension, 2.0 m (6.6 ft) 7.4 Operating the heavy load lattice extension

7.4.3

G

Procedure if permissible wind speeds are exceeded Risk of accidents at excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

This will prevent the truck crane overturning due to overload.

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

• Make sure that you follow the instructions for checking the wind speed;

à Lifting capacity table and Operating Instructions GMK4080-2.

If the maximum permissible wind speed is exceeded An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

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

7.4.4

Instructions for turning loads over

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à Driving with a rigged crane, p. 11 - 1.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension, 2.0 m (6.6 ft) 7.5 Maintenance

7.5

Maintenance

H 7.5.1

If the heavy load lattice extension has been in storage for an extended period of time, perform maintenance work on it no later than when it is next used.

Maintenance plan M 1

M1

Maintenance work on the HEAVY LOAD LATTICE EXTENSION: Monthly/after about 100 oper. hrs.

Heavy load lattice extension

à p. 7 - 50

– Lubricate the pins

7.5.2

Maintenance plan M 3

M3

Maintenance work on the HEAVY LOAD LATTICE EXTENSION: Every three months/after 250 oper. hrs.

Heavy load lattice extension

à p. 7 - 50

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– Check the sheaves

Operating instructions for lattice extension GMK4080-2

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7 - 49

Heavy load lattice extension, 2.0 m (6.6 ft) 7.5 Maintenance

7.5.3

Description of maintenance work Grease1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE part-no.1)

KP - 1K - 50

DIN 51825

03233369

à Maintenance manual

Prerequisite – The truck crane must be secured to prevent unauthorised use; Maintenance manual.

à

or – The heavy load lattice extension is removed.

M1 – Lubricate the pins

• Grease the pins (1).

M3 – Check the sheaves

• Check the deflection sheave (2) and head sheave (3) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or

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

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.1 Operations planning

8

Heavy load lattice extension 1.8 m (5.9 ft)

8.1

Operations planning

8.1.1

Possible operating modes Operating mode with the hoist rope The sheaves package (1) is installed.

The load hangs on the hoist rope and is lifted using the hoist.

Operating mode with shackle1) The shackle (2) is installed.

The load hangs on the shackle and is lifted using the derricking gear.

Extra uitrusting

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1)

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8-1

Heavy load lattice extension 1.8 m (5.9 ft) 8.1 Operations planning

8.1.2

Assembly Permissible combinations

8.1.3

G

Combination

Designation

Y

Sections used

A

Heavy load lattice extension 1.8 m (5.9 ft)

1.8 m (5.9 ft)

6

Identification Risk of accidents if heavy load lattice extensions are interchanged!

Install only the heavy load lattice extension that belongs to the truck crane.

No other heavy load lattice extensions may be installed.

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The truck crane and the corresponding section 6 must be labelled with the same serial number (1).

8-2

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.1 Operations planning

8.1.4

G

Slinging points Risk of accidents if used improperly!

Attach parts only at the designated slinging points. Use only lifting gear and joining elements of sufficient load bearing capacity.

Heavy load lattice extension Slinging points The slinging points (1) are marked with stickers (2).

• Attach the heavy load lattice extension at a 0° angle on the hook (1).

Weight The sticker (3) gives data on the weight and the necessary lifting gear.

Guide rope – With an installed sheaves package

• Fasten the guide rope to the folded out rope attachment point (1); p. 8 - 35.

à Folding out,

– With installed shackle

• Fasten the guide rope to the head piece (2)

à Folding in

s

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or the folded in shackle (3); the shackle, p. 8 - 52.

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8-3

Heavy load lattice extension 1.8 m (5.9 ft) 8.1 Operations planning

Sheaves package

à Transport dimensions and weights, p. 8 - 5 • Sling the sheaves package at the middle sheave.

Shackle

à Transport dimensions and weights, p. 8 - 5

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• Fasten the sling gear directly to the shackle.

8-4

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.1 Operations planning

8.1.5

Transport dimensions and weights

Heavy load lattice extension

Section

Version

Length x width x height in m (ft)

Weight in kg (lbs)

6

With sheaves package

2.03 x 0.86 x 1.40 (6.7 x 2.8 x 4.6)

360(794)

Shackle Designation

(L) x (W) x (H) in m (ft)

Weight in kg (lbs)

Shackle

0.61 x 0.25 x 0.25 2.00 x 0.85 x 0.85

46 102

Designation

(L) x (W) x (H) in m (ft)

Weight in kg (lbs)

Complete sheaves package

0.40 x 0.36 x 0.20 (1.31 x 1.20 x 0.66)

21 (49)

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Sheaves package

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8-5

Heavy load lattice extension 1.8 m (5.9 ft) 8.1 Operations planning

8.1.6

Transport condition

Removed

• Check that the heavy lattice load extension is in the transport condition or establish this now, if necessary.

– The pins (1) are secured in the holders.

– The plug (2) is closed with a cap and the cable (3) is wound onto the holder.

– The pins (4) are secured in the connecting points.

– The lifting limit switch (5) is removed.

– The 0° angle position must be set and the pin (6) must be inserted and secured.

– With an installed sheaves package – the rope attachment point (7) is folded in; p. 8 - 35.

à

– With an installed shackle – the shackle (8) p. 8 - 52. is folded in;

à

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– Section 6 must be secured to a suitable support.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.1 Operations planning

Folded

• Check that the heavy lattice load extension is in the transport condition or establish this now, if necessary.

– The pins (3) are secured in the holders.

– The plug (2) is closed with a cap and the cable (1) is wound onto the holder.

– The pins (4) are secured in the connecting points.

– The lifting limit switch (5) is removed.

– The 0° angle position must be set and the pin (6) must be inserted and secured.

– With an installed sheaves package – the rope attachment point (7) is folded in; p. 8 - 35.

à

– With an installed shackle – the shackle (8) p. 8 - 52. is folded in;

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à

Operating instructions for lattice extension GMK4080-2

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8-7

Heavy load lattice extension 1.8 m (5.9 ft) 8.1 Operations planning

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Blank page

8-8

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

8.2

Checklists for rigging work

8.2.1

Overview The distinction is made between various different procedures.

– Installation and removal These procedures have to be performed when the heavy load lattice extension is transported separately. The installation and removal of the heavy load lattice extension is described.

– Rigging These procedures must be performed when the heavy load lattice extension is being transported on the crane. The changeover between the transport position and the operating position is described.

The table shows which checklist is applicable to any required rigging work.

Required rigging work – Installing the heavy load lattice extension

– Removing the heavy load lattice extension

– In working position

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) installation into the working position, p. 8 - 10

– In transport position

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) installation into the transport position, p. 8 - 13

– From operating position

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) removal from the working position, p. 8 - 15

– From transport position

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) removal from the transport position, p. 8 - 18

– In working position

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) rigging into the working position, p. 8 - 20

– In transport position

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) rigging into the transport position, p. 8 - 23

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– Rigging the heavy load lattice extension

checklist

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8-9

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

8.2.2

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) installation into the working position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V. – The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– An auxiliary crane must be available.

2. If necessary, install the sheaves package or shackle; Installing/removing the air traffic control light, p. 8 - 48, Installing/removing the shackle, p. 8 - 50.

à à

à Removed, p. 8 - 6.

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3. Check the transport condition of section 6;

8 - 10

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

4. – Fasten slings to section 6 and attach a guide rope.

– Lift section 6 into position in front of the main boom.

à Identification, p. 8 - 2 à Transport dimensions and weights, p. 8 - 5 à Slinging points, p. 8 - 3 5. – Establish a mechanical connection between section 6 and the main p. 8 - 27. boom;

à

– Remove the lifting gear and the guide rope.

6. Adjust the angle position if necessary;

à p. 8 - 36.

7. With an installed sheaves package – Position the hoist rope on section 6 and reeve the hook block.

Section 6 – Fitting/removing the hoist rope, p. 8 - 40 Possible reeving methods on the heavy load lattice extension, p. 8 - 41

à à

à p. 8 - 43.

– Attach the lifting limit switch weight; à Operating instructions – Install the lifting limit switch;

GMK4080-2.

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8 - 11

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

8. With installed shackle – Fold out the shackle;

à p. 8 - 52.

– Roll the hoist rope onto the drum or reeve it onto the main boom.

– Switch off the hoists.

9. If necessary, install the anemometer and air traffic control light; p. 8 - 45.

à

10. If necessary, mount the camera;

à p. 8 - 46.

11. Check the horizontal alignment of the truck crane and correct it if Operating instructions GMK4080-2. necessary;

à

à p. 8 - 53.

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12. Enter and confirm the current rigging mode;

8 - 12

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

8.2.3

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) installation into the transport position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V. – The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– An auxiliary crane must be available.

2. If necessary, install the sheaves package or shackle; Installing/removing the air traffic control light, p. 8 - 48, Installing/removing the shackle, p. 8 - 50.

à à

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Operating instructions for lattice extension GMK4080-2

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8 - 13

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

3. Check the transport condition of section 6;

à Removed, p. 8 - 6.

4. – Fasten slings to section 6 and attach a guide rope.

– Lift section 6 into position at the main boom.

à Identification, p. 8 - 2 à Transport dimensions and weights, p. 8 - 5 à Slinging points, p. 8 - 3

5. Establish a mechanical connection between section 6 and the main boom; p. 8 - 28.

à

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6. Remove the lifting gear and the guide rope.

8 - 14

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

8.2.4

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) removal from the working position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V. – The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– An auxiliary crane must be available.

2. If necessary, remove the anemometer and air traffic control light; p. 8 - 45.

à

3. If necessary, remove the camera;

à p. 8 - 46.

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8 - 15

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

4. With an installed sheaves package – Remove the lifting limit switch weight; GMK4080-2 – Remove the lifting limit switch;

à Operating instructions

à p. 8 - 44.

– Set down the hook block, unreeve the hoist rope and remove it from section 6 if necessary; p. 8 - 40.

à

– Adjust to a 0° angle position, if necessary;

à p. 8 - 36.

– Reeve the hoist rope onto the main boom head, or roll it on to the drum; Operating instructions GMK4080-2.

à

5. With installed shackle

à p. 8 - 52.

– Adjust to a 0° angle position, if necessary;

à p. 8 - 36.

– If necessary, roll the hoist rope onto the drum or reeve it onto the main boom; Operating instructions GMK4080-2.

à

8 - 16

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Operating instructions for lattice extension GMK4080-2

19.06.2019

– Fold in the shackle;

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

6. Fasten slings to section 6 and attach a guide rope.

à Identification, p. 8 - 2 à Transport dimensions and weights, p. 8 - 5 à Slinging points, p. 8 - 3

7. Disconnect the connection between section 6 and the main boom; p. 8 - 27.

à

8. Lift section 6 off the main boom and put it aside.

9. Remove the lifting gear and the guide rope.

à p. 8 - 6.

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10. Check the transport condition of section 6;

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8 - 17

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

8.2.5

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) removal from the transport position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V. – The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– Section 6 is folded up against the side of the main boom;

à p. 8 - 7.

– An auxiliary crane must be available.

2. Fasten slings to section 6 and attach a guide rope.

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à Identification, p. 8 - 2 à Transport dimensions and weights, p. 8 - 5 à Slinging points, p. 8 - 3

8 - 18

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

3. Disconnect the connection between section 6 and the main boom; p. 8 - 28.

à

4. Lift section 6 off the main boom and put it aside.

5. Remove the lifting gear and the guide rope.

à p. 8 - 6.

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6. Check the transport condition of section 6;

Operating instructions for lattice extension GMK4080-2

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8 - 19

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

8.2.6

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) rigging into the working position

H

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

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V. – The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

– Section 6 is folded up against the side of the main boom;

2. Fasten the guide rope to section 6;

à p. 8 - 7.

à p. 8 - 3.

3. – Move section 6 into the working position;

à p. 8 - 30.

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– Remove the guide rope.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

4. Adjust the angle position if necessary;

à p. 8 - 36.

5. If necessary, install the sheaves package or shackle; Installing/removing the air traffic control light, p. 8 - 48, Installing/removing the shackle, p. 8 - 50.

à à

6. With an installed sheaves package – Position the hoist rope on section 6 and reeve the hook block; Section 6 – Fitting/removing the hoist rope, p. 8 - 40.

Possible reeving methods on the heavy load lattice extension, p. 8 - 41

à à

à p. 8 - 43.

– Attach the lifting limit switch weight; à Operating instructions – Install the lifting limit switch;

GMK4080-2.

7. With installed shackle – Fold out the shackle;

à p. 8 - 52.

– Roll the hoist rope onto the drum or reeve it onto the main boom.

– Switch off the hoists.

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s

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8 - 21

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

8. If necessary, install the anemometer and air traffic control light; p. 8 - 45.

à

9. If necessary, mount the camera;

à p. 8 - 46.

10. Check the horizontal alignment of the truck crane and correct it if necessary; Operating instructions GMK4080-2.

à

à p. 8 - 53.

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11. Enter and confirm the current rigging mode;

8 - 22

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

8.2.7

CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) rigging into the transport position

H

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

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is supported on outriggers; GMK4080-2.

à Operating instructions

– The appropriate counterweight for the crane operation must be rigged; Operating instructions GMK4080-2.

à

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section V. – The main boom is lowered to the horizontal position; Operating instructions GMK4080-2.

à

2. If necessary, remove the anemometer and air traffic control light; p. 8 - 45.

à

3. If necessary, remove the camera;

à p. 8 - 46.

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8 - 23

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

4. With an installed sheaves package – Remove the lifting limit switch weight; GMK4080-2 – Remove the lifting limit switch;

à Operating instructions

à p. 8 - 44.

– Set down the hook block, unreeve the hoist rope and remove it from section 6 if necessary; p. 8 - 40.

à

– Adjust to a 0° angle position, if necessary;

à p. 8 - 36.

– Reeve the hoist rope onto the main boom head, or roll it on to the drum; Operating instructions GMK4080-2.

à

5. With installed shackle

à p. 8 - 52.

– Adjust to a 0° angle position, if necessary;

à p. 8 - 36.

– If necessary, roll the hoist rope onto the drum or reeve it onto the main boom; Operating instructions GMK4080-2.

à

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Operating instructions for lattice extension GMK4080-2

19.06.2019

– Fold in the shackle;

Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

6. Fasten the guide rope to section 6;

à p. 8 - 3.

7. Move section 6 into the transport position;

à p. 8 - 32.

8. Remove the lifting gear and the guide rope.

à p. 8 - 7.

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9. Check the transport position of section 6;

Operating instructions for lattice extension GMK4080-2

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Heavy load lattice extension 1.8 m (5.9 ft) 8.2 Checklists for rigging work

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Blank page

8 - 26

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3

Rigging work

8.3.1

Section 6/main boom – Establish/separate the connection in the working position

G

Risk of accidents due to swinging parts!

Always secure the sections with a guide rope from the ground before establishing or separating connections.

This prevents you from being crushed or caught by swinging sections.

– Section 6 must be attached to an auxiliary crane.

– A guide rope must be attached.

Connecting

• Align the connecting points (1).

• Remove the pins (2) from the holders (3) and insert them into the connecting points (1) at both sides.

• Secure the pins.

Disconnecting

• Remove the pins (2) from the connecting points (1) and insert them into the clamps (3) at both sides.

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• Secure the pins.

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8 - 27

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.2

G

Section 6/main boom– Establish/separate the connection in the transport position Risk of accidents due to swinging parts!

Always secure the sections with a guide rope from the ground before establishing or separating connections.

This prevents you from being crushed or caught by swinging sections.

– Section 6 must be attached to an auxiliary crane.

– A guide rope must be attached.

Connecting

• Remove the pins (1) and (3) from the connecting points (2) and (4).

• Lift section 6 onto the side of the main boom.

• Align the connecting point (4) on section 6 and the holder(5).

• Fit the pin (3) into the connecting point (4) and secure it.

• Swing section 6 so that the connecting point (2) is aligned.

• Fit the pin (1) into the connecting point (2)

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and secure it.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

Disconnecting

• Remove the pins (1) and (3) from the connecting points (2) and (4).

• Lift section 6 from the main boom and put it aside.

• Fit the pin (1) into the connecting point (2) and secure it.

• Fit the pin (3) into the connecting point (4)

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and secure it.

Operating instructions for lattice extension GMK4080-2

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8 - 29

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.3

Bringing section 6 from the transport position into the working position – A guide rope must be attached.

• Remove the pin (1) from the connecting point (2).

• Swing the heavy load lattice extension to the main boom head until the connecting points (7) are aligned.

G

Risk of accidents due to the heavy load lattice extension falling down!

Always first establish a connection to the main boom head before separating the connection to the basic section.

This way, you can avoid the heavy load lattice extension having no connection with the main boom and falling down.

• Remove the pins (6) from the clamps (5).

• Insert the pins (6) into the connecting points (7) and secure them.

• Fit the pin (1) into the connecting point (2) and secure it.

• Remove the pin (3) from the connecting

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point (4).

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

• Swing the heavy load lattice extension in front of the main boom head until the connecting points (1) are aligned.

• Remove the pins (2) from the clamps (5).

• Insert the pins (2) into the connecting points (1) and secure them.

• Fit the pin (3) into the connecting point (4)

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and secure it.

Operating instructions for lattice extension GMK4080-2

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8 - 31

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.4

Bringing section 6 from the working position into the transport position – A guide rope must be attached.

• Remove the pins (2) from the connecting points (1).

• Insert the pins (2) into the clamps (5) and secure them.

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

S

Risk of damage to driver's cab!

Make sure that the shackle is folded in and a 0° angle position is set before swinging the heavy load lattice extension onto the main boom. This prevents the driver's cab from being damaged.

• Swing the heavy load lattice extension onto the main boom until the

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connecting point (4) is aligned.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

G

Risk of accidents due to the heavy load lattice extension falling down!

Always first establish a connection to the basic section before separating the connection to the main boom head.

This way, you can avoid the heavy load lattice extension having no connection with the main boom and falling down.

• Fit the pin (3) into the connecting point (4) and secure it.

• Remove the pin (1) from the connecting point (2).

• Remove the pins (6) from the connecting points (7).

• Insert the pins (6) into the clamps (5) and secure them.

• (A) – Swing the heavy load lattice extension onto the main boom until the connecting point (2) is aligned.

• (B) – Fit and secure the pin (1) in the connect-

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ing point (2).

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8 - 33

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

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Blank page

8 - 34

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.5

S

Folding the rope attachment point in/out Risk of damage when the rope attachment point is folded out!

Always fold the rope attachment point in for transport and for operation with an odd number of lines. This prevents the rope attachment point from being damaged or the rope attachment point and hoist rope from being damaged during operation.

Folding out

• (A) – Hold the rope attachment point (3) tight and remove the rod (2).

• (B) – Fold the rope attachment point (3) downwards.

• Insert the rod (2) into the connecting points (1) and secure it.

Folding in

• (A) – Remove the rod (2).

• (B) – Fold the rope attachment point (3) upwards.

• Secure the rope attachment point – insert

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the rod (2) into the connecting points (1) and secure it.

Operating instructions for lattice extension GMK4080-2

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8 - 35

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.6

Section 6 – Setting the angle - with the hoist rope The angle can also be set using a chain hoist;

G

à p. 8 - 38.

Danger of uncontrolled movements!

Always secure the angle piece with the hoist rope before removing any pins. This prevents the heavy load lattice extension from folding down in an uncontrolled manner.

Fastening the hoist rope

• Unreel the hoist rope up to the heavy load lattice extension.

• Fasten the padlock (1) to the connecting point (2).

S

Risk of damage!

Raise and lower the heavy load lattice extension only slowly and carefully using the hoist and do not pull the heavy load lattice extension against the end stop. This prevents damage to the rope sheaves, hoist rope or parts of the heavy load lattice extension.

– Adjusting to a 0° angle

• Use the hoist to lift the heavy load lattice extension (4) all the way to the end stop.

• Withdraw the pin (2) from the bore (3) and insert it into the connecting point (1).

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• Secure the pins (2).

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

– Adjusting to a 27° angle

• Use the hoist to lift the heavy load lattice extension until the load on the pin in the connecting point (1) is relieved.

• Withdraw the pin (2) from the connecting point (1) and insert it into the bore (3).

• Secure the pins (2).

• Use the hoist to lower the heavy load lattice extension (4) all the way to the end stop.

Removing the hoist rope

• Relieve the load on the padlock (1) back and remove it from the connecting point (2).

When rigging in the transport position or when a shackle is mounted

• Remove the hoist rope from the sheave (4)

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and secure the rod (3).

Operating instructions for lattice extension GMK4080-2

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8 - 37

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.7

Section 6 – Setting the angle - with a chain hoist The angle can also be set using the hoist rope;

G

à p. 8 - 36.

Danger of uncontrolled movements!

Always secure the angle piece with the chain hoist before removing any pins. This prevents the heavy load lattice extension from folding down in an uncontrolled manner.

Attaching the chain hoist

• Attach the chain hoist (3) at the slinging points (1) and (2).

Adjusting to a 0° angle

• (A) – Use the chain hoist to lift the heavy load lattice extension until the load is relieved from the pin (1).

• (B) – Insert the pin (1) into the bore (2).

• (C) – Use the chain hoist to lift the heavy load lattice extension all the way to the end stop.

• Insert the pin (1) into the connecting point (3).

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• Secure the pin (1).

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

Adjusting to a 27° angle

• (A) – Use the chain hoist to lift the heavy load lattice extension until the load is relieved from the pin (1).

• (B) – Insert the pin (1) into the bore (2).

• (C) – Use the chain hoist to lower the heavy load lattice extension all the way to the end stop.

• Insert the pin (1) into the connecting point (3).

• Secure the pin (1).

S

Risk of damage during crane operation!

Always remove the chain hoist before starting crane operation.

This prevents overloading of the chain hoist and prevents damage resulting from a collision between chain hoist components and the crane.

Removing the chain hoist The 0° or 27° angle has been set.

• Unload the chain hoist (3).

• Remove the chain hoist from the slinging

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points (1) and (2).

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8 - 39

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.8

Section 6 – Fitting/removing the hoist rope

G

Risk of accidents due to falling parts!

Always secure the sheaves and rods with retaining pins.

This prevents sections coming loose, falling out and causing injuries.

Fitting

• Remove the rods (1).

• For operating with an even number of lines – fold out the rope attachment point (4); p. 8 - 35.

à

• Guide the hoist rope over the sheaves (2) and (3).

• Reeve the hoist rope – in accordance with the reeving images;

à p. 8 - 41.

• Insert the rods (1) and secure them.

Removing

H

If the angle position needs to be set during further rigging, then remove the hoist rope only from the sheave (3).

• Remove the rods (1).

• Unreeve the hoist rope.

• Remove the hoist rope from the sheaves (2) and (3).

• Fold the rope attachment point (4) in;

à p. 8 - 35.

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• Insert the rods (1) and secure them.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

s 8.3.9

Possible reeving methods on the heavy load lattice extension For straight reeving, the hoist rope is attached to the rope attachment point (1).

Reeve the hoist rope on the hook block; GMK4080-2.

à Operating instructions

3 sheave hook block Reeving A

6-fall

B

5-fall

C

4-fall

D

3-fall

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8 - 41

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

1 sheave hook block Reeving A

3-fall

B

2-fall

C

1-fall

Hook tackle Reeving 1-fall

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A

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.10

Installing/removing the lifting limit switch

Installation

If only a single lifting limit switch is available you must use the lifting limit switch belonging to the main boom; Operating instructions GMK4080-2.

à

If several lifting limit switches are available, all those lifting limit switches on the main boom from which no lifting limit switch weight is suspended must be overridden; Operating instructions GMK4080-2.

à

• Unwind the cable (3) from the clamp (4).

• Insert the plug (2) in the socket (1).

• Lay the cable so that it will not be damaged during crane operation.

• Plug the lifting limit switch (6) into the clamp (5).

• Secure the lifting limit switch.

• Wind up the cable (3) far enough onto the clamp (4) so that it does not sag down.

• Insert the plug (2) in the socket (1).

• Install the lifting limit switch weight (7) and lay it around the hoist rope; Operating instructions GMK4080-2.

à

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8 - 43

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

Removing

• Pull the plug (2) out of the socket (1) and close it with the cap.

• Wind the cable (3) on to the clamp (4).

• Cover the socket (1) with the cap.

• Remove the lifting limit switch weight (7);

à Operating instructions GMK4080-2.

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

• Unwind the cable (3) from the clamp (4).

• Cover the socket (1) with the cap.

• Remove the lifting limit switch (6) from the clamp (5).

• Stow the lifting limit switch so that it is safe in traffic, or install it on the main boom; Operating instructions GMK4080-2.

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à

8 - 44

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.11

S

Installing / removing the anemometer and air traffic control light Risk of damage during on-road driving and operating in halls!

Always remove the anemometer and air traffic control light before on-road driving and operating in halls.

This prevents the specified overall height from being exceeded at on-road level, and the anemometer from being damaged due to unfavourable air currents or collision with the hall ceiling.

You must install the anemometer on the main boom for operation with the heavy load lattice extension.

You must remove the anemometer for transportation and operation in a hall.

Installation and removal are performed in the same way as for main boom Operating instructions GMK4080-2. operation;

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à

Operating instructions for lattice extension GMK4080-2

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8 - 45

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.12

Installing/removing the camera For crane operation you must install the camera and switch it on.

For on-road driving, you must switch the camera off and remove it.

Operating the camera;

à Operating instructions GMK4080-2.

Installation

• Insert the camera (2) into the clamp (1) and secure it.

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

• Lay the cable (5) so that it will not be damaged during crane operation.

• Remove the cable (3) from the clamp (4).

• Insert the plug (2) in the socket (1).

• Lay the cable (3) so that it will not be

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damaged during crane operation.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

Removing

• Take the plug (3) out of the socket (4) and close the socket with the cap.

• Remove the camera (2) from the clamp (1) and insert the retaining pin in the clamp.

• Stow away the camera so that it will not be damaged during crane operation.

• Take the plug (2) out of the socket (1) and close the socket with the cap.

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• Fasten the cable (3) on the clamp (4).

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8 - 47

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.13

Installing/removing the air traffic control light Swing the heavy load lattice extension in front of the main boom or perform the heavy load lattice extension on the ground.

In the transport position, the area (1) cannot be accessed safely and falling parts can damage the driver's cab.

Installing

• If necessary, remove the shackle; à p. 8 - 51.

• Sling the sheaves package; à p. 8 - 4.

• Remove the rods (4).

• Remove the pins (1) and pull the axle (2) out of the connecting points (3).

• Align the sheaves package so that the connecting points (3) are aligned.

• Insert the axle (2) into the connecting points (3).

• Insert the pin (1) and secure it.

• Insert the rods (4) and secure them.

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• Remove the lifting gear.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

Removing

G

You must remove the sheaves package for operation with the shackle.

Risk of injury due to falling sheaves package!

Always secure the sheaves package prior to removal. This will prevent the sheaves package from falling and causing injury to you or other persons when the axle is pulled out.

• Sling the sheaves package; à p. 8 - 4.

• Remove the rods (4).

• Remove the pins (1) and pull the axle (2) out of the connecting points (3).

• Lift the sheaves package out.

• Insert the axle (2) into the connecting points (3).

• Insert the pin (1) and secure it.

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• Insert the rods (4) and secure them.

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8 - 49

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.14

Installing/removing the shackle Swing the heavy load lattice extension in front of the main boom or perform the heavy load lattice extension on the ground.

In the transport position, the clearance (1) is too small and the shackle would damage the driver's cab during installation or removal.

Installing

• If necessary, remove the sheaves package; à p. 8 - 49.

• Sling the shackle; à p. 8 - 4.

• Remove the rods (4).

• Remove the pins (1) and pull the axle (2) out of the connecting points (3).

• Align the shackle so that the connection points (3) are aligned.

• Insert the axle (2) into the connecting points (3).

• Insert the pin (1) and secure it.

• Fold the shackle down and remove the lifting gear.

• Insert the rods (4) and secure them.

It may be necessary to fold in the shackle; p. 8 - 52.

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à

8 - 50

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

Removing

G

You must remove the shackle for operation with the sheaves package.

Risk of injury due to falling shackle!

Always secure the shackle prior to removal. This will prevent the shackle from falling and causing injury to you or other persons when the axle is pulled out.

• Remove the rods (4).

• Sling the shackle; à p. 8 - 4.

• Turn the shackle upwards.

• Remove the pins (1) and pull the axle (2) out of the connecting points (3).

• Lift the shackle out.

• Insert the axle (2) into the connecting points (3).

• Insert the pin (1) and secure it.

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• Insert the rods (4) and secure them.

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8 - 51

Heavy load lattice extension 1.8 m (5.9 ft) 8.3 Rigging work

8.3.15

Folding in/folding out the shackle You must always fold in the shackle before swinging the heavy load lattice extension into the transport position or before setting the main boom down on the boom rest.

When the shackle is folded out, the clearance (1) is too small and the shackle would damage the driver's cab.

Folding in the shackle

• Remove the rod from the holes (1).

• Fold the shackle to the rear and insert the rod into the holes (2).

• Secure the rod.

Folding out the shackle

• Lift the shackle and remove the rod from the holes (2).

• Fold the shackle downwards.

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• Secure the rod in the holes (1).

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.4 Heavy load lattice extension – Operation with hoist rope

8.4

Heavy load lattice extension – Operation with hoist rope The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will need for a rigged or folded heavy load lattice extension.

8.4.1

Setting the RCL

Input

• You can enter the current rigging mode with the heavy load lattice extension via the RCL code or via the individual components.

– Via the RCL code

• Select the RCL code (1) corresponding to the current rigging mode on the display (2) according to the Lifting capacity table.

– Via individual components

• Select and conform the slewing range, outrigger span, and counterweight for the current rigging mode.

• Select the symbol (1) heavy load lattice extension for the boom system.

• Select and confirm the current rigging mode.

2 The length of the heavy load lattice extension 3 The angle of the heavy load lattice extension 4 The current reeving on the heavy load lattice extension for the hoisting gear whose hoist rope is reeved on the heavy load lattice extension

• Confirm the entry with the symbol (5).

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s Operating instructions for lattice extension GMK4080-2

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8 - 53

Heavy load lattice extension 1.8 m (5.9 ft) 8.4 Heavy load lattice extension – Operation with hoist rope

Shutdown

Operation with the heavy load lattice extension is monitored by the RCL. When operating with the heavy load lattice extension, RCL shutdowns may occur for the same reasons as when operating with the main boom; Operating instructions GMK4080-2.

à

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table .

– During operation with the heavy load lattice extension If a hook block (3) is reeved at the main boom, then the displayed current load (1) is influenced by – the weight of the lifted load (2) and – the weight of the hook block (3).

– During main boom operation If a heavy load lattice extension is installed, then the displayed current load (1) – the weight of the lifted load (2) and – the weight of the heavy load lattice extension (4)and – the weight of the hook block (3) at the heavy load lattice extension.

à

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H

The lifting capacity tables contain information for operations planning specifying the values which must be subtracted from the specified maximum load bearing capacities for certain rigging modes; Remarks about working with the heavy load lattice extension.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.4 Heavy load lattice extension – Operation with hoist rope

8.4.2

Derricking, telescoping the main boom

Slewing range of 360°

G

Risk of accidents if the RCL is overridden!

Do not override the RCL when lowering the boom into horizontal position.

If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The requirements that must be satisfied before the raising, lowering and telescoping of the main boom with rigged heavy load lattice extension are permitted, for a slewing range of 360° are monitored by the RCL. Observe the information in the Rigging tables section of the Lifting capacity table.

Note that the hook block or load can hit the heavy load lattice extension or the main boom when using large boom angles, 0° angle position and short slings.

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The RCL switches off the raising of the boom when the minimum permitted working radius has been reached.

Operating instructions for lattice extension GMK4080-2

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Heavy load lattice extension 1.8 m (5.9 ft) 8.4 Heavy load lattice extension – Operation with hoist rope

8.4.3

G

Procedure if permissible wind speeds are exceeded Risk of accidents at excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

This will prevent the truck crane overturning due to overload.

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

• Make sure that you follow the instructions for checking the wind speed;

à Lifting capacity table and Operating Instructions GMK4080-2.

If the maximum permissible wind speed is exceeded An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

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

8.4.4

Instructions for turning loads over

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à Driving with a rigged crane, p. 11 - 1.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.5 Heavy load lattice extension – Operation with a shackle

8.5

Heavy load lattice extension – Operation with a shackle • Switch off the hoists to secure them against unintentional use – the displays (1) must be red.

The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains additional information that you will need for a rigged heavy load lattice extension with shackle.

8.5.1

Setting the RCL

Input

• You can enter the current rigging mode with the heavy load lattice extension via the RCL code or via the individual components.

– Via the RCL code

• Select the RCL code (1) corresponding to the current rigging mode on the display (2) according to the Lifting capacity table.

– Via individual components

• Select and conform the slewing range, outrigger span, and counterweight for the current rigging mode.

• Select the symbol (1) heavy load lattice extension - operation with shackle for the boom system.

• Select and confirm the current rigging mode.

2 The length of the heavy load lattice extension 3 The angle of the heavy load lattice extension

• Confirm the entry with the symbol (4).

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Heavy load lattice extension 1.8 m (5.9 ft) 8.5 Heavy load lattice extension – Operation with a shackle

Shutdown

Operation with the heavy load lattice extension is monitored by the RCL. When operating with the heavy load lattice extension, RCL shutdowns may occur for the same reasons as when operating with the main boom; Operating instructions GMK4080-2.

à

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table.

– During operation with the heavy load lattice extension If a hook block (3) is reeved at the main boom, then the displayed current load (1) is influenced by – the weight of the lifted load (2) and – the weight of the hook block (3).

– During main boom operation If a heavy load lattice extension is installed, then the displayed current load (1) – the weight of the lifted load (2) and – the weight of the hook block (3) and – the weight of shackle (4) and – The weight of the heavy load lattice extension (5).

à

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H

The lifting capacity tables contain information for operations planning specifying the values which must be subtracted from the specified maximum load bearing capacities for certain rigging modes; Remarks about working with the heavy load lattice extension.

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Heavy load lattice extension 1.8 m (5.9 ft) 8.5 Heavy load lattice extension – Operation with a shackle

8.5.2

Derricking the main boom The derricking gear is operated in the same way as in main boom operation.

G Lifting the load

Risk of accidents if the RCL is overridden!

Never override the RCL when derricking.

If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

Lifting a load by derricking or telescoping is expressly prohibited in the Operating instructions supplied. Operation of the heavy load lattice extension with a shackle is a special case in which lifting of the load is only enabled under specific conditions. prerequisites – The current rigging mode with heavy load lattice extension and shackle is confirmed.

– The main boom is at a telescope status that is enabled according to the rigging table corresponding to the displayed RCL code.

– The load to be lifted is no greater than the displayed maximum load.

An RCL shutdown due to overload occurs when the system detects that the load is too heavy when raising the boom – the lamps (1) light up.

• In this case, stop raising the boom immediately.

Raising of the boom is shut down automatically in the system with Version A RCL override.

G

Risk of overturning when raising the boom after shutdown!

Stop raising the boom immediately. If an automatic shutdown occurs when raising the boom, then never use an RCL override to enable raising of the boom or higher degree of utilisation (these functions are only provided for rigging without a raised load). The crane will be overloaded if you continue raising the boom.

If the load cannot be detached from the shackle because the lifting gear is tensioned then you must lower the boom in order to leave the shutdown range.

With Version A RCL override you must override the RCL shutdown for this. Only use the In an emergency override type; Operating instructions GMK4080-2. Lower the boom only once after overriding, in order to set the load down or relieve the tension on the lifting gear.

à

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Heavy load lattice extension 1.8 m (5.9 ft) 8.5 Heavy load lattice extension – Operation with a shackle

Derricking

Lowering the boom to a horizontal position is enabled within the working ranges of the lifting capacity tables for operation with a shackle. Observe the information in the Lifting capacity table provided.

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Note that the load (1) can hit the heavy load lattice extension (2) when using large boom angles, 0° angle position and short slings.

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Heavy load lattice extension 1.8 m (5.9 ft) 8.5 Heavy load lattice extension – Operation with a shackle

8.5.3

Telescoping the main boom The telescoping mechanism is operated in the same way as in main boom operation.

There are no separate lifting capacity tables for telescoping lengths and intermediate lengths. Telescoping is performed using a confirmed RCL code for operation with a shackle at fixed lengths.

Telescoping is only enabled for the telescoping distances specified in the lifting capacity table.

Telescoping without a load The specified loads (3) are enabled for all displayed telescoping distances in the angle ranges (1) and (2).

Telescoping with a load Over the telescoping distances specified with the arrows (4), below the main boom angle (1), the loads specified in the loading capacity tables for fixed lengths when operating with a shackle are enabled. The maximum telescoping is 50/50/50/50/50 in this case.

G

Risk of accidents if the RCL is overridden!

Never override the RCL when telescoping.

If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

When telescoping, the maximum permissible load is continuously calculated and shown on the display (1).

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The maximum permissible load reduces when telescoping out. An RCL shutdown occurs when the value corresponds to the current load.

In this case, you can only leave the shutdown range by retracting.

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Heavy load lattice extension 1.8 m (5.9 ft) 8.5 Heavy load lattice extension – Operation with a shackle

8.5.4

G

Procedure if permissible wind speeds are exceeded Risk of accidents at excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

This will prevent the truck crane overturning due to overload.

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

• Make sure that you follow the instructions for checking the wind speed;

à Lifting capacity table and Operating Instructions GMK4080-2.

If the maximum permissible wind speed is exceeded An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

• Put the truck crane into the rigging mode specified for the current wind

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speed in the lifting capacity table.

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Operating instructions for lattice extension GMK4080-2

Heavy load lattice extension 1.8 m (5.9 ft) 8.6 Maintenance

8.6

Maintenance

H 8.6.1

If the heavy load lattice extension has been in storage for an extended period of time, perform maintenance work on it no later than when it is next used.

Maintenance plan M 1

M1

Maintenance work on the HEAVY LOAD LATTICE EXTENSION: Monthly/after about 100 oper. hrs.

Heavy load lattice extension

à p. 8 - 64

– Lubricate the pins

8.6.2

Maintenance plan M 3

M3

Maintenance work on the HEAVY LOAD LATTICE EXTENSION: Every three months/after 250 oper. hrs.

Heavy load lattice extension

à p. 8 - 64

– Check the sheaves

8.6.3

Maintenance plan M 12

M 12

Maintenance work on the HEAVY LOAD LATTICE EXTENSION: Annually/after about 1000 oper. hrs.

Heavy load lattice extension

à p. 8 - 64

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– Lubricate the shackle

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Heavy load lattice extension 1.8 m (5.9 ft) 8.6 Maintenance

8.6.4

Description of maintenance work Grease1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE Part no.1)

KP - 1K - 50

DIN 51825

03233369

à Maintenance manual

Prerequisite – The truck crane must be secured to prevent unauthorised use; Maintenance manual.

à

or – The heavy load lattice extension is removed.

M1 – Lubricate the pins

• Clean the pins (1) and lubricate them with a brush.

M3 – Check the sheaves

• Check the deflection sheave (2) and head sheave (3) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled sheaves replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

M12 – Lubricate the shackle

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• Clean all lubricating nipples (1) and lubricate them with a grease gun.

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Operating instructions for lattice extension GMK4080-2

Auxiliary single-sheave boom top 9.1 Operations planning

9

Auxiliary single-sheave boom top

9.1

Operations planning

9.1.1

Identification and slinging points

G G

Risk of accidents when using an incorrect auxiliary single-sheave boom top Install only an auxiliary single-sheave boom top that belongs to the truck crane. No other auxiliary single-sheave boom tops may be installed.

Risk of accidents if used improperly Only fit slings to the auxiliary single-sheave boom top at the slinging points provided. Use only lifting gear and joining elements of sufficient load bearing capacity.

Slinging point The slinging point (1) is marked with a sticker (2).

Attach the lifting gear to the upper part (1) of the auxiliary single-sheave boom top.

Weight The sticker (3) gives the weight and the necessary lifting gear.

Identification The crane and the corresponding auxiliary single-sheave boom top must be labelled with the same serial number (4).

Guide rope

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Fasten the guide rope (5) to the auxiliary single-sheave boom top.

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9-1

Auxiliary single-sheave boom top 9.1 Operations planning

9.1.2

9.1.3

S G

Transport dimensions and weights

Section

Length x width x height in m (ft)

Weight in kg (lbs)

Auxiliary single-sheave boom top

1.00 x 0.40 x 1.00 (3.3 x 1.3 x 3.3)

60 (135)

Transport condition Risk of damage to the auxiliary single-sheave boom top Always secure the auxiliary single-sheave boom top by tying it down with suitable belts when it is being transported on a separate vehicle. This prevents the auxiliary single-sheave boom top tipping over and becoming damaged during transport.

Risk of injury if the pins are not secured Before transporting, make sure that all pins are secured in their holders with retaining pins. Secure any pins that are not secure.

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

Removed

• Check that the equipment is secured in transport condition and secure it now if necessary: – All 4 pins (1) must be secured in the connecting points.

– The auxiliary single-sheave boom top must be placed on a suitable support and secured.

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– The lifting limit switch (2) and lifting limit switch weight (3) must be removed and stowed in a manner that is safe for driving on roads.

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Auxiliary single-sheave boom top 9.1 Operations planning

Installed

• Check that the equipment is secured in transport condition and secure it now if necessary: – The lifting limit switch (1) and lifting limit switch weight (2) must be removed and stowed in a manner that is safe for driving on roads.

– The auxiliary single-sheave boom top is folded on the main boom.

– The two pins (3) are inserted in the connecting points (4) and are secured.

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– The two pins (5) are inserted in the connecting points (6) and are secured.

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9-3

Auxiliary single-sheave boom top 9.1 Operations planning

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Blank page

9-4

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Operating instructions for lattice extension GMK4080-2

Auxiliary single-sheave boom top 9.2 Description of the rigging work

9.2

Description of the rigging work

9.2.1

Moving the auxiliary single-sheave boom top into operating position

G

Risk of accidents due to swinging sections Always secure the sections with a guide rope from the ground before establishing or disconnecting connections.

This prevents you from being crushed or caught by swinging sections.

After transport on a separate vehicle

• Sling the auxiliary single-sheave boom top to an auxiliary crane;

à p. 9 - 1.

• Remove the pin (1) from the connecting point (2).

• Lift the auxiliary single-sheave boom top in front of the main boom so that the connection points (2) are aligned.

• Swing the auxiliary single-sheave boom top in front of the main boom.

• Fit the pin (3) into the connecting points (5) and secure it.

• Remove the pins (4) from the holders (3) and insert them into the connecting points (5).

Secure the pins.

• Remove the lifting gear.

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• Remove the guide rope.

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9-5

Auxiliary single-sheave boom top 9.2 Description of the rigging work

After transport on the main boom

• Attach a guide rope.

• Remove the pin (1) from the connecting point (2).

• Swing the auxiliary single-sheave boom top in front of the main boom.

• Remove the pins (3) from the holders (4) and insert them into the connecting points (5).

Secure the pins.

• Insert the pin (1) into the connecting point (2).

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• Remove the guide rope.

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Operating instructions for lattice extension GMK4080-2

Auxiliary single-sheave boom top 9.2 Description of the rigging work

9.2.2

G

Moving the auxiliary single-sheave boom top into the transport position Risk of accidents due to swinging sections Always secure the sections with a guide rope from the ground before establishing or disconnecting connections.

This prevents you from being crushed or caught by swinging sections.

For transport on a separate vehicle

• Sling the auxiliary single-sheave boom top to an auxiliary crane;

à p. 9 - 1.

• Remove the pins (3) from the connecting points (5) and insert them into the holders (4). Secure the pins.

• Remove the pin (1) from the connecting point (2).

• Lift the auxiliary single-sheave boom top from the head of the main boom.

• Fit the pin (1) into the connecting point (2) and secure it.

• Set down the auxiliary single-sheave boom top;

à p. 9 - 2.

• Remove the lifting gear.

• Remove the guide rope.

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9-7

Auxiliary single-sheave boom top 9.2 Description of the rigging work

For transport on the main boom

• Remove the pins (3) from the connecting points (5) and insert them into the holders (4).

• Remove the pin (1) from the connecting point (2).

• Swing the auxiliary single-sheave boom top onto the side of the main boom.

• Fit the pin (1) into the connecting point (2) and secure it.

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• Remove the guide rope.

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Operating instructions for lattice extension GMK4080-2

Auxiliary single-sheave boom top 9.2 Description of the rigging work

9.2.3

G

Installing/removing a folded auxiliary single-sheave boom top Risk of accidents due to swinging sections Always secure the sections with a guide rope from the ground before establishing or disconnecting connections.

This prevents you from being crushed or caught by swinging sections.

Installing

• Sling the auxiliary single-sheave boom top to an auxiliary crane;

à p. 9 - 1.

• Remove the pins (1) and (3) from the connecting points (2) and (4).

• Lift the auxiliary single-sheave boom top up to the main boom so that the connection point (4) is aligned.

• Insert the pin (1) into the connecting point (2). Secure the pin.

• Fold the auxiliary single-sheave boom top onto the main boom so that the connection points (4) are aligned.

• Insert the pin (3) into the connecting point (4). Secure the pin.

• Remove the lifting gear.

• Remove the guide rope.

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9-9

Auxiliary single-sheave boom top 9.2 Description of the rigging work

Removing

• Sling the auxiliary single-sheave boom top to an auxiliary crane;

à p. 9 - 1.

• Remove the pins (1) and (3) from the connecting points (2) and (4).

• Lift the auxiliary single-sheave boom top away from the main boom.

• Insert the pins (1) and (3) into the connecting points (2) and (4). Secure the pins.

• Set down the auxiliary single-sheave boom top so it is safe for on-road transport; p. 9 - 2.

à

• Remove the lifting gear.

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• Remove the guide rope.

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Operating instructions for lattice extension GMK4080-2

Auxiliary single-sheave boom top 9.2 Description of the rigging work

9.2.4

Attaching/removing the hoist rope You can use the rigging hook for this;

G

à p. 3 - 13.

Risk of accidents due to falling parts Always secure the sheaves and rods with retaining pins.

This prevents parts coming loose, falling out and causing injuries.

Fitting

• Remove the rods (3).

• Guide the hoist rope over the sheaves (1) and (2).

• Insert the rods (3).

• Secure the rods.

Removing

• Remove the rods (3).

• Remove the hoist rope from the sheaves (2) and (1).

• Insert the rods (3).

• Secure the rods.

Reeving options 1-sheave hook block and hook tackle Reeving 1-fall

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A

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9 - 11

Auxiliary single-sheave boom top 9.2 Description of the rigging work

9.2.5

Installing/removing the lifting limit switch

Installing

If only a single lifting limit switch is available you must use the lifting limit switch belonging to the main boom; Operating instructions GMK4080-2.

à

If several lifting limit switches are available, you must override all the lifting limit switches connected to the main boom which do not have a lifting limit switch weight suspended from them; Operating instructions GMK4080-2.

à

– After separate transport

• Insert the lifting limit switch into the holder (6) and secure it.

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

– After transport on the auxiliary singlesheave boom top

• Unwind the cable (3) from the holder (7).

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

• Lay the cable (3) so that it will not be damaged during crane operation.

• Install the lifting limit switch weight (5) and

à Operating

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lay it around the hoist rope; instructions GMK4080-2.

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Operating instructions for lattice extension GMK4080-2

Auxiliary single-sheave boom top 9.2 Description of the rigging work

Removing

• Remove the lifting limit switch weight (3);

à Operating instructions GMK4080-2.

• Take the plug (2) out of the socket (1) and close the socket with the cap.

• Close off the plug (2) with the cap.

– For separate transport

• Remove the lifting limit switch (4) from the holder (3).

– For transport on the auxiliary single-sheave boom top

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• Wind the cable (1) onto the holder (2).

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9 - 13

Auxiliary single-sheave boom top 9.2 Description of the rigging work

9.2.6

S

Installing/removing the anemometer and air traffic control light Risk of damage during on-road driving and indoor operation Always remove the anemometer and air traffic control light before on-road driving and before operating indoors (in a hangar, for example).

This prevents the specified overall height for on-road level from being exceeded, and the anemometer from getting damaged due to unfavourable air currents or collision with a ceiling.

Installing and removing You must install the anemometer for operation with the auxiliary singlesheave boom top.

You must remove the anemometer for transport and for operation indoors (in a hangar, for example).

Installation and removal are performed in the same way as for main boom operation; Operating instructions GMK4080-2.

à

9.2.7

Installing/removing the camera Installing and removing You can mount the camera on the main boom for operation with the auxiliary single-sheave boom top.

For transport you must remove the camera.

It is installed and removed in the same way as for working with the main operating instructions GMK4080-2. boom;

à

à Operating instructions.

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Operating the camera;

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Operating instructions for lattice extension GMK4080-2

Auxiliary single-sheave boom top 9.3 Operation with the auxiliary single-sheave boom top

9.3

Operation with the auxiliary single-sheave boom top The raising, lowering, slewing and derricking movements and telescoping of the main boom are carried out in the same way as for operation with the main boom. This section only contains information that you need for a rigged or folded auxiliary single-sheave boom top.

9.3.1

Setting the RCL

Input

• On the RCL, enter the current rigging mode for operation with the main boom. Do so either using the corresponding RCL code in accordance with the lifting capacity table (1) or via individual components (2).

• Enter the current reeving on the auxiliary single-sheave boom top into the RCL for the hoist whose hoist rope is reeved to the auxiliary single-sheave boom top.

• Confirm the entry.

H

The lifting capacity for the RCL code is enabled once the telescopic sections are locked.

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9 - 15

Auxiliary single-sheave boom top 9.3 Operation with the auxiliary single-sheave boom top

Shutdown

Operation with the auxiliary single-sheave boom top is monitored by the RCL. When operating with the auxiliary single-sheave boom top, RCL shutdowns may occur for the same reasons as when operating with the main boom; Operating instructions GMK4080-2.

à

In certain rigging modes, the RCL shuts down even when loads are lifted that are lighter than the maximum load bearing capacity specified in the lifting capacity table.

– During operation with the auxiliary single-sheave boom top If a hook block (3) is reeved on the main boom, then the displayed current load (1) is affected by: – The weight of the lifted load (2) and – The weight of the hook block (3) and – The weight of the auxiliary single-sheave boom top (4)

– During main boom operation If an auxiliary single-sheave boom top (4) is installed, then the displayed current load (1) is affected by: – The weight of the lifted load (2) and – The weight of the hook block (3) and

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– The weight of the auxiliary single-sheave boom top (4)

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Operating instructions for lattice extension GMK4080-2

Auxiliary single-sheave boom top 9.3 Operation with the auxiliary single-sheave boom top

9.3.2

G

Procedure if permissible wind speeds are exceeded Risk of accidents due to excessively high wind speeds If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

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

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

• Make sure that you observe the specifications for monitoring the wind speed;

à Lifting capacity table and Operating instructions GMK4080-2.

If the maximum permitted wind speed is exceeded Automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

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

9.3.3

Instructions for turning loads over

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à Turning loads over, p. 10 - 1.

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Auxiliary single-sheave boom top 9.3 Operation with the auxiliary single-sheave boom top

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Operating instructions for lattice extension GMK4080-2

Auxiliary single-sheave boom top 9.4 Maintenance

9.4

Maintenance

H 9.4.1

If the auxiliary single-sheave boom top has been in storage for an extended period of time, perform maintenance work on it no later than when it is next used.

Maintenance plan M 1

M1

Maintenance work on the AUXILIARY SINGLE-SHEAVE BOOM TOP: monthly/after approx. 100 oper. hrs Auxiliary single-sheave boom top

à p. 9 - 20

– Lubricate the pins

9.4.2

Maintenance plan M 3

M3

Maintenance work on the AUXILIARY SINGLE-SHEAVE BOOM TOP: every three months/after 250 oper. hrs Auxiliary single-sheave boom top

à p. 9 - 20

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– Check the sheaves

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9 - 19

Auxiliary single-sheave boom top 9.4 Maintenance

9.4.3

Description of maintenance work Grease 1) Grease 1)

Designation to DIN 51502

Specification classification

GROVE part no.1)

KP - 1K - 50

DIN 51825

03233369

à Maintenance manual Lubricate the pins

• Grease the pins (1), (3) and (4).

Check the sheaves

• Check the sheaves (2) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled

19.06.2019

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

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Operating instructions for lattice extension GMK4080-2

Turning loads over

10

Turning loads over Turning loads over is permitted only with: – Swing-away lattice – Heavy load lattice extension – Auxiliary single-sheave boom top

G Prerequisites

Risk of accidents due to incorrect procedure Before turning loads, observe all the prerequisites specified in this section and proceed exactly as described. This way, you avoid accidents due to overload.

– The main hoist rope must be reeved on the main boom.

– The auxiliary hoist rope must be reeved on the lattice extension.

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– The main hoist rope must be reeved with at least the same number of falls as the auxiliary hoist rope.

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10 - 1

Turning loads over 10.1 Setting the RCL

10.1

Setting the RCL

Entering the reeving

Before lifting the load, you must enter the number of currently reeved falls for both hoists into the RCL, so that the data is immediately available should you subsequently wish to switch over to the main hoist after turning the load over.

Main hoist

• Select the symbol (1) and confirm your selection.

• Select the current reeved number of falls, for example, 3.

• Confirm the entry.

Auxiliary hoist

• Select the symbol (2) and confirm your entry.

• Select the current reeved number of falls, for example, 2.

• Confirm the entry.

Switching over to the auxiliary hoist

The load must first be lifted using the auxiliary hoist.

Turning a load over requires use of both hoists simultaneously. The RCL always uses the reeving data for the first hoist to be switched on.

• Switch off both hoists – symbols (1) and (2) display red.

• Switch on the auxiliary hoist – symbol (2) displays green.

• Switch on the main hoist – symbol (1) displays green.

• Enter the RCL code that corresponds to the rigging mode according to the lifting capacity table for the rigged lattice extension.

19.06.2019

The RCL now factors in: – The reeving for the auxiliary hoist and – The lifting capacity tables for the lattice extension.

10 - 2

3 302 915 en

Operating instructions for lattice extension GMK4080-2

Turning loads over 10.2 Turning a load over

10.2

Turning a load over

H

Before turning a load over, check that this procedure is in accordance with the regulations in the country in which you are working.

• Check that all the prerequisites have been met;

à Prerequisites, p. 10 - 1.

• Check that the RCL is correctly set;

à Prerequisites, p. 10 - 1.

G H

Risk of accidents due to overloading Ensure that the RCL is set for operation with the lattice extension during the entire procedure and move the load only at minimum speed.

In this way you prevent the crane becoming overloaded.

Once as the load is suspended on two hooks, there will be slight deviations in the Current load display. However, these deviations are on the safe side with regard to RCL shutdown.

Turning a load over is performed the same way, irrespective of which of the permitted lattice extensions is used. In this section the illustration shows a lattice extension which is used to symbolically represent all the other options.

• (A) – Lift the load completely with the lattice extension.

• (B) – Sling the load additionally on the main boom.

• (C) – Lift the load with the main hoist till both the slinging points are at the same height.

• (D) – Lower the load with the auxiliary hoist until the load is completely suspended from the main hoist rope.

19.06.2019

• Detach the auxiliary hoist rope from the load.

Switching over to the main hoist • Switch the auxiliary hoist off – the RCL will now use the reeving data for the main hoist.

• After the load has been set down, enter the RCL code appropriate to the boom system that will be used for the next lift.

Operating instructions for lattice extension GMK4080-2

3 302 915 en

10 - 3

Turning loads over 10.2 Turning a load over

19.06.2019

Blank page

10 - 4

3 302 915 en

Operating instructions for lattice extension GMK4080-2

Driving with a rigged crane 11.1 Safety instructions

11

Driving with a rigged crane

11.1

Safety instructions

Risk of overturning by slewing the superstructure When driving the rigged truck crane, the slewing gear must be switched off – slewing gear brake engaged.

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

Risk of tipping over when driving the rigged truck crane Driving with a rigged truck crane is an operating mode which must be carried out with the utmost care. Be sure to always observe all specifications and safety instructions in the Operating instructions GMK40802.

19.06.2019

G G G G

Risk of accidents due to partially obstructed view of the truck crane When driving the truck crane, always stay in visual or radio contact with a banksman who can observe the parts you are unable to see, e.g. the raised main boom in the 0° to the rear position.

Operating instructions for lattice extension GMK4080-2

3 302 915 en

11 - 1

Driving with a rigged crane 11.2 Driving path

11.2

Driving path The path to be driven must be level. Uneven surfaces cannot be compensated with the level adjustment system.

The entire driving distance must be level. The rigging modes and axle loads specified in this chapter are only valid for driving paths which are free of inclines in longitudinal and lateral direction.

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

19.06.2019

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

11 - 2

3 302 915 en

Operating instructions for lattice extension GMK4080-2

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

11.3

Permissible rigging modes and axle loads Depending on the counterweight and lattice extension rigged, you must bring the superstructure, the main boom and the lattice extension into certain positions so that the permissible axle loads are not exceeded.

S

Risk of damage to the axle lines Move the superstructure, the main boom and the lattice extension into the specified positions only. This prevents excessive strain on the axle lines.

• Enter the RCL code for the actual rigging mode and actual outrigger span of the truck crane in accordance with the lifting capacity table.

G

Risk of accidents if the RCL is overridden Always enter the RCL code for the current rigging mode. The specified positions are within the monitored working ranges.

If the RCL is overridden, the truck crane may overturn even if you move it into the positions specified.

• Bring the superstructure, the main boom and the lattice extension into the position specified for the rigged counterweight in the following tables.

• Tie down the hook block so that it cannot swing around.

Notes on the tables

H

All axle loads specified apply to 445/95 R 25 (16.00 R25) tyres on steel rims.

In the case of different tyres, the axle load changes by double the weight Operating instructions GMK4080-2, section Technical difference of a wheel; data, Spare wheel.

à

Note on the specified angle ranges The specified maximum axle load is only reached at the limits of the listed angle range for the main boom, e.g. at 20° or 70°. If the maximum axle load is reached at the front, it will be below the maximum value at the rear and vice versa.

The axle loads are below the specified maximum axle loads within the listed angle range.

The following applies to the footnotes in the table: 1)

19.06.2019

2)

Rear:

Slewing angle display 0°

Front:

Slewing angle display 180°

Front:

on each of the first and second axle lines

Rear:

on each of the third and fourth axle lines

s Operating instructions for lattice extension GMK4080-2

3 302 915 en

11 - 3

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

11.3.1

Swing-away lattice

Swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft)

All axle loads specified apply with a reeved 3-sheave hook block, weight 450 kg (990 lbs).

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-0-0-0-0

Lattice extension angle in °

Superstru cture position1)

40 - 80

0 - 40

0-0-0-0-0

55 - 82

0-0-0-0-0

Front

Rear

Front

12.5 (27.5)

13.5 (29.7)

0 - 40

Rear

11.5 (25.3)

13.5 (29.7)

40 - 70

0 - 40

Front

11.5 (25.3)

14.5 (32.0)

0-0-0-0-0

45 - 82

0 - 40

Rear

12.5 (27.5)

14.5 (32.0)

0-0-0-0-0

40 - 65

0 - 40

Front

11.5 (25.3)

14.5 (32.0)

0-0-0-0-0

45 - 82

0 - 40

Rear

13.0 (28.6)

14.5 (32.0)

0-0-0-0-0

40 - 65

0 - 40

Front

11.0 (24.2)

15.5 (34.2)

0-0-0-0-0

40 - 82

0 - 40

Rear

13.5 (29.7)

15.0 (33.1)

0-0-0-0-0

40 - 60

0 - 40

Front

10.5 (23.1)

15.5 (34.2)

0-0-0-0-0

40 - 82

0 - 40

Rear

14.0 (30.8)

15.5 (34.2)

0-0-0-0-0

40 - 55

0 - 40

Front

10.5 (23.1)

15.5 (34.2)

0-0-0-0-0

40 - 82

0 - 40

Rear

14.5 (32.0)

15.5 (34.2)

0-50-0-0-0

40 - 65

0 - 40

Front

12.5 (27.5)

16.5 (36.4)

0-0-0-0-0

40 - 82

0 - 40

Rear

15.0 (33.1)

15.5 (34.2)

0.5 t (1,102 lbs)

3.4 t (7,496 lbs)

4.5 t (9,921 lbs)

5.7 t (12,566 lbs)

6.8 t (14,991 lbs)

8.0 t (17,637 lbs)

9.1 t (20,062 lbs)

11 - 4

Maximum axle load 2) in t (x 1,000 lbs)

3 302 915 en

Operating instructions for lattice extension GMK4080-2

19.06.2019

Counterwe ight in t (lbs)

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

Counterwe ight in t (lbs)

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-50-0-0-0

Lattice extension angle in °

Superstru cture position1)

40 - 60

0 - 40

0-0-0-0-0

40 - 82

0-50-0-0-0

Maximum axle load 2) in t (x 1,000 lbs) Front

Rear

Front

12.5 (27.5)

16.5 (36.4)

0 - 40

Rear

15.5 (34.2)

15.5 (34.2)

40 - 60

0 - 40

Front

12.0 (26.4)

17.5 (38.6)

0-0-0-0-0

40 - 82

0 - 40

Rear

16.5 (36.4)

15.5 (34.2)

0-50-0-0-0

40 - 55

0 - 40

Front

11.5 (25.3)

17.5 (38.6)

0-0-0-0-0

40 - 82

0 - 40

Rear

17.0 (37.5)

15.5 (34.2)

50-50-0-0-0

40 - 60

0 - 40

Front

14.5 (32.0)

17.0 (37.5)

0-0-0-0-0

40 - 82

0 - 40

Rear

17.5 (38.6)

15.5 (34.2)

50-50-0-0-0

40 - 60

0 - 40

Front

14.0 (30.8)

18.0 (39.7)

0-0-0-0-0

40 - 82

0 - 40

Rear

18.0 (39.7)

15.5 (34.2)

10.2 t (22,487 lbs)

11.4 t (25,133 lbs)

12.5 t (27,558 lbs)

13.7 t (30,203 lbs)

14.8 t (32,628 lbs)

1) 2)

à Notes on the tables, p. 11 - 3

19.06.2019

,

Operating instructions for lattice extension GMK4080-2

3 302 915 en

11 - 5

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

Counterwe ight in t (lbs)

All axle loads specified apply with a reeved 3-sheave hook block, weight 450 kg (990 lbs).

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-0-0-0-0

Lattice extension angle in °

Superstru cture position1)

40 - 80

0 - 40

0-0-0-0-0

60 - 82

0-0-0-0-0

Front

Rear

Front

13,5 (29,7)

13,5 (29,7)

0 - 40

Rear

11,5 (25,3)

13,5 (29,7)

40 - 70

0 - 40

Front

12.5 (27.5)

14.0 (30.8)

0-0-0-0-0

55 - 82

0 - 40

Rear

12.5 (27.5)

14.5 (32.0)

0-0-0-0-0

40 - 70

0 - 40

Front

12.0 (26.4)

15.0 (33.1)

0-0-0-0-0

50 - 82

0 - 40

Rear

13.0 (28.6)

15.0 (33.1)

0-0-0-0-0

40 - 65

0 - 40

Front

12.0 (26.4)

15.0 (33.1)

0-0-0-0-0

50 - 82

0 - 40

Rear

13.5 (29.7)

15.0 (33.1)

0-0-0-0-0

40 - 65

0 - 40

Front

11.5 (25.3)

16.0 (35.4)

0-0-0-0-0

45 - 82

0 - 40

Rear

14.0 (30.8)

16.0 (35.4)

0-0-0-0-0

40 - 60

0 - 40

Front

11.5 (25.3)

16.0 (35.4)

0-0-0-0-0

45 - 82

0 - 40

Rear

14.5 (32.0)

16.0 (35.4)

0-0-0-0-0

40 - 55

0 - 40

Front

11.0 (24.2)

16.0 (35.4)

0-0-0-0-0

40 - 82

0 - 40

Rear

15.0 (33.1)

16.5 (36.4)

0-50-0-0-0

40 - 65

0 - 40

Front

13.5 (29.7)

17.0 (37.5)

0-0-0-0-0

40 - 82

0 - 40

Rear

15.5 (34.2)

16.5 (36.4)

0.5 t (1,102 lbs)

3.4 t (7,496 lbs)

4.5 t (9,921 lbs)

5.7 t (12,566 lbs)

6.8 t (14,991 lbs)

8.0 t (17,637 lbs)

9.1 t (20,062 lbs)

10.2 t (22,487 lbs)

11 - 6

Maximum axle load 2) in t (x 1,000 lbs)

3 302 915 en

Operating instructions for lattice extension GMK4080-2

19.06.2019

Swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft)

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

Counterwe ight in t (lbs)

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-50-0-0-0

Lattice extension angle in °

Superstru cture position1)

40 - 60

0 - 40

0-0-0-0-0

40 - 82

0-50-0-0-0

Maximum axle load 2) in t (x 1,000 lbs) Front

Rear

Front

13.0 (28.6)

17.0 (37.5)

0 - 40

Rear

16.0 (35.4)

16.5 (36.4)

40 - 60

0 - 40

Front

12.5 (27.5)

18.0 (39.7)

0-0-0-0-0

40 - 82

0 - 40

Rear

16.5 (36.4)

16.5 (36.4)

0-50-0-0-0

40 - 55

0 - 40

Front

12.5 (27.5)

17.5 (38.6)

0-0-0-0-0

40 - 82

0 - 40

Rear

17.5 (38.6)

16.5 (36.4)

50-50-0-0-0

40 - 60

0 - 40

Front

15.0 (33.1)

17.5 (38.6)

0-0-0-0-0

40 - 82

0 - 40

Rear

18.0 (39.7)

16.5 (36.4)

11.4 t (25,133 lbs)

12.5 t (27,558 lbs)

13.7 t (30,203 lbs)

14.8 t (32,628 lbs)

1) 2)

à Notes on the tables, p. 11 - 3

19.06.2019

,

Operating instructions for lattice extension GMK4080-2

3 302 915 en

11 - 7

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

11.3.2

Boom extension

Boom extension 7.7 + 13.8 m (23.6 + 45.3 ft)

All axle loads specified apply with a reeved 3-sheave hook block, weight 450 kg (990 lbs).

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-0-0-0-0

Lattice extension angle in °

Superstru cture position1)

50 - 80

0 - 40

0-0-0-0-0

65 - 82

0-0-0-0-0

Front

Rear

Front

13.0 (28.6)

13.5 (29.7)

0 - 40

Rear

11.0 (24.2)

13.5 (29.7)

40 - 75

0 - 40

Front

14.0 (30.8)

15.0 (33.1)

0-0-0-0-0

60 - 82

0 - 40

Rear

12.5 (27.5)

14.5 (32.0)

0-0-0-0-0

40 - 70

0 - 40

Front

13.5 (29.7)

14.5 (32.0)

0-0-0-0-0

60 - 82

0 - 40

Rear

13.0 (28.6)

14.5 (32.0)

0-0-0-0-0

40 - 70

0 - 40

Front

13.0 (28.6)

15.5 (34.2)

0-0-0-0-0

55 - 82

0 - 40

Rear

13.5 (29.7)

15.5 (34.2)

0-0-0-0-0

40 - 65

0 - 40

Front

13.0 (28.6)

15.5 (34.2)

0-0-0-0-0

55 - 82

0 - 40

Rear

14.0 (30.8)

15.5 (34.2)

0-0-0-0-0

40 - 65

0 - 40

Front

12.5 (27.5)

16.5 (36.4)

0-0-0-0-0

50 - 82

0 - 40

Rear

14.5 (32.0)

16.5 (36.4)

0-0-0-0-0

40 - 60

0 - 40

Front

12.5 (27.5)

16.0 (35.4)

0-0-0-0-0

50 - 82

0 - 40

Rear

15.0 (33.1)

16.5 (36.4)

0.5 t (1,102 lbs)

3.4 t (7,496 lbs)

4.5 t (9,921 lbs)

5.7 t (12,566 lbs)

6.8 t (14,991 lbs)

8.0 t (17,637 lbs)

9.1 t (20,062 lbs)

11 - 8

Maximum axle load 2) in t (x 1,000 lbs)

3 302 915 en

Operating instructions for lattice extension GMK4080-2

19.06.2019

Counterwe ight in t (lbs)

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

Counterwe ight in t (lbs)

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-0-0-0-0

Lattice extension angle in °

Superstru cture position1)

40 - 60

0 - 40

0-0-0-0-0

50 - 82

0-50-0-0-0

Maximum axle load 2) in t (x 1,000 lbs) Front

Rear

Front

12.0 (26.4)

17.0 (37.5)

0 - 40

Rear

15.5 (34.2)

16.5 (36.4)

40 - 65

0 - 40

Front

14.5 (32.0)

17.5 (38.6)

0-0-0-0-0

45 - 82

0 - 40

Rear

16.0 (35.4)

17.5 (38.6)

0-50-0-0-0

40 - 60

0 - 40

Front

14.0 (30.8)

17.0 (37.5)

0-0-0-0-0

40 - 82

0 - 40

Rear

16.5 (36.4)

18.0 (39.7)

0-50-0-0-0

40 - 60

0 - 40

Front

14.0 (30.8)

18.0 (39.7)

0-0-0-0-0

40 - 82

0 - 40

Rear

17.0 (37.5)

18.0 (39.7)

0-50-0-0-0

40 - 55

0 - 40

Front

13.5 (29.7)

17.5 (38.6)

0-0-0-0-0

40 - 82

0 - 40

Rear

17.5 (38.6)

18.0 (39.7)

10.2 t (22,487 lbs)

11.4 t (25,133 lbs)

12.5 t (27,558 lbs)

13.7 t (30,203 lbs)

14.8 t (32,628 lbs)

1) 2)

à Notes on the tables, p. 11 - 3

19.06.2019

,

Operating instructions for lattice extension GMK4080-2

3 302 915 en

11 - 9

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

11.3.3

Heavy load lattice extension 2.0 m (6.6 ft)

Heavy load lattice extension 2.0 m (6.6 ft)

All axle loads specified apply with a reeved 3-sheave hook block, weight 450 kg (990 lbs).

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-0-0-0-0

Lattice extension angle in °

Superstru cture position1)

20

0 - 40

0-0-0-0-0

80

0-0-0-0-0

Front

Rear

Front

13.5 (29.8)

9.0 (19.8)

0 - 40

Rear

9.0 (19.8)

12.0 (26.5)

20

0 - 40

Front

13.0 (28.7)

10.0 (22.0)

0-0-0-0-0

80

0 - 40

Rear

10.0 (22.0)

12.5 (27.6)

0-0-0-0-0

20

0 - 40

Front

12.0 (26.5)

11.5 (25.4)

0-0-0-0-0

80

0 - 40

Rear

11.0 (24.3)

12.5 (27.6)

0-0-0-0-0

20

0 - 40

Front

11.5 (25.4)

12.5 (27.6)

0-0-0-0-0

80

0 - 40

Rear

11.5 (25.4)

12.5 (27.6)

0-0-0-0-5

20

0 - 40

Front

12.5 (27.6)

13.0 (28.7)

0-0-0-0-0

80

0 - 40

Rear

12.5 (27.6)

13.0 (28.7)

0-0-0-5-5

20 - 30

0 - 40

Front

13.0 (28.7)

14.5 (32.0)

0-0-0-0-0

80

0 - 40

Rear

14.0 (30.9)

13.0 (28.7)

0-0-5-5-5

20 - 30

0 - 40

Front

15.0 (33.1)

14.0 (30.9)

0-0-0-0-0

60 - 80

0 - 40

Rear

15.0 (33.1)

16.0 (35.3)

0.5 t (1,102 lbs)

3.4 t (7,496 lbs)

4.5 t (9,921 lbs)

5.7 t (12,566 lbs)

6.8 t (14,991 lbs)

8.0 t (17,637 lbs)

9.1 t (20,062 lbs)

11 - 10

Maximum axle load 2) in t (x 1,000 lbs)

3 302 915 en

Operating instructions for lattice extension GMK4080-2

19.06.2019

Counterwe ight in t (lbs)

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

Counterwe ight in t (lbs)

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-0-0-0-0

Lattice extension angle in °

Superstru cture position1)

5 - 45

0 - 40

0-0-0-0-0

5 - 70

0-50-0-0-0

Maximum axle load 2) in t (x 1,000 lbs) Front

Rear

Front

10.5 (23.1)

16.5 (36.4)

0 - 40

Rear

14.0 (30.8)

16.0 (35.4)

5 - 55

0 - 40

Front

13.5 (29.7)

17.0 (37.5)

0-0-0-0-0

5 - 70

0 - 40

Rear

14.5 (32.0)

16.0 (35.4)

0-50-0-0-0

5 - 50

0 - 40

Front

13.0 (28.6)

17.0 (37.5)

0-0-0-0-0

5 - 70

0 - 40

Rear

15.0 (33.1)

16.0 (35.4)

0-50-0-0-0

5 - 50

0 - 40

Front

12.5 (27.5)

18.0 (39.7)

0-0-0-0-0

5 - 70

0 - 40

Rear

15.5 (34.2)

16.5 (36.4)

0-50-0-0-0

5 - 45

0 - 40

Front

12.5 (27.5)

18.0 (39.7)

0-0-0-0-0

5 - 70

0 - 40

Rear

16.0 (35.4)

16.5 (36.4)

10.2 t (22,487 lbs)

11.4 t (25,133 lbs)

12.5 t (27,558 lbs)

13.7 t (30,203 lbs)

14.8 t (32,628 lbs)

1) 2)

à Notes on the tables, p. 11 - 3

19.06.2019

,

Operating instructions for lattice extension GMK4080-2

3 302 915 en

11 - 11

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

11.3.4

Heavy load lattice extension 1.8 m (5.9 ft)

Heavy load lattice extension 1.8 m (5.9 ft)

All axle loads specified apply with a reeved 3-sheave hook block, weight 450 kg (990 lbs).

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-0-0-0-0

Lattice extension angle in °

Superstru cture position1)

5 - 59

0 - 27

0-0-0-0-0

45 - 59

0-0-0-0-0

Front

Rear

Front

13.5 (29.7)

11.0 (24.2)

0 - 27

Rear

8.5 (18.8)

13.5 (29.7)

5 - 59

0 - 27

Front

12.5 (27.5)

13.0 (28.6)

0-0-0-0-0

35 - 59

0 - 27

Rear

9.5 (21.0)

14.5 (32.0)

0-0-0-0-0

5 - 59

0 - 27

Front

12.0 (26.4)

14.0 (30.8)

0-0-0-0-0

35 - 59

0 - 27

Rear

10.0 (22.0)

14.5 (32.0)

0-0-0-0-0

5 - 59

0 - 27

Front

12.0 (26.4)

14.5 (32.0)

0-0-0-0-0

30 - 59

0 - 27

Rear

10.5 (23.1)

15.0 (33.1)

0-0-0-0-0

5 - 59

0 - 27

Front

11.5 (25.3)

15.5 (34.2)

0-0-0-0-0

20 - 59

0 - 27

Rear

11.0 (24.2)

15.5 (34.2)

0-0-0-0-0

5 - 55

0 - 27

Front

11.0 (24.2)

16.0 (35.4)

0-0-0-0-0

10 - 59

0 - 27

Rear

11.5 (25.3)

16.0 (35.4)

0-0-0-0-0

5 - 50

0 - 27

Front

11.0 (24.2)

16.5 (36.4)

0-0-0-0-0

5 - 59

0 - 27

Rear

12.0 (26.4)

16.0 (35.4)

0.5 t (1,102 lbs)

3.4 t (7,496 lbs)

4.5 t (9,921 lbs)

5.7 t (12,566 lbs)

6.8 t (14,991 lbs)

8.0 t (17,637 lbs)

9.1 t (20,062 lbs)

11 - 12

Maximum axle load 2) in t (x 1,000 lbs)

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Operating instructions for lattice extension GMK4080-2

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Counterwe ight in t (lbs)

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

Counterwe ight in t (lbs)

Telescoping Telescope section I-II-III-IV-V in %

Main boom angle in °

0-0-0-0-0

Lattice extension angle in °

Superstru cture position1)

5 - 45

0 - 27

0-0-0-0-0

5 - 59

0-50-0-0-0

Maximum axle load 2) in t (x 1,000 lbs) Front

Rear

Front

10.5 (23.1)

16.5 (36.4)

0 - 27

Rear

12.5 (27.5

16.0 (35.4)

5 - 55

0 - 27

Front

13.5 (29.7)

17.0 (37.5)

0-0-0-0-0

5 - 59

0 - 27

Rear

13.0 (28.6)

16.5 (36.4)

0-50-0-0-0

5 - 50

0 - 27

Front

13.0 (28.6)

17.0 (37.5)

0-0-0-0-0

5 - 59

0 - 27

Rear

13.5 (29.7)

16.5 (36.4)

0-50-0-0-0

5 - 50

0 - 27

Front

13.0 (28.6)

18.0 (39.7)

0-0-0-0-0

5 - 59

0 - 27

Rear

14.0 (30.8)

16.5 (36.4)

0-50-0-0-0

5 - 45

0 - 27

Front

12.5 (27.5)

18.0 (39.7)

0-0-0-0-0

5 - 59

0 - 27

Rear

15.0 (33.1)

16.5 (36.4)

10.2 t (22,487 lbs)

11.4 t (25,133 lbs)

12.5 t (27,558 lbs)

13.7 t (30,203 lbs)

14.8 t (32,628 lbs)

1) 2)

à Notes on the tables, p. 11 - 3

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,

Operating instructions for lattice extension GMK4080-2

3 302 915 en

11 - 13

Driving with a rigged crane 11.3 Permissible rigging modes and axle loads

11.3.5

Auxiliary single-sheave boom top • When driving with a rigged auxiliary single-sheave boom top, proceed in

à Operating

19.06.2019

the same way as for driving with a rigged truck crane; instructions GMK4080-2.

11 - 14

3 302 915 en

Operating instructions for lattice extension GMK4080-2

Driving with a rigged crane 11.4 Before driving

11.4

Before driving • Before driving you must perform all steps described here in order, while also observing all specifications and safety instructions in the corresponding sections of the operating manual provided; Operating instructions GMK4080-2.

à

– Secure the superstructure against slewing – Check the tyre pressures and wind speed – Set the truck crane on the wheels – Select the driving direction and switch on the separate steering (transmission/connections)

11.5

While driving The same specifications, restrictions and safety instructions applying to driving a rigged truck crane without a rigged lattice extension also apply to driving a rigged truck crane with a rigged lattice extension.

For safety reasons, the outrigger beams should remain extended to the extent permitted by the space available. The outrigger pads may not touch the ground while driving the crane.

• Observe all specifications and safety instructions in the corresponding sections of the operating manual provided; GMK4080-2.

11.6

à Operating instructions

After driving • After driving you must perform the same steps as those required after driving a rigged truck crane without a rigged lattice extension. When doing this you must also observe all specifications and safety instructions in the corresponding section of the operating manual provided; Operating instructions GMK4080-2.

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à

Operating instructions for lattice extension GMK4080-2

3 302 915 en

11 - 15

Driving with a rigged crane 11.6 After driving

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Blank page

11 - 16

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Operating instructions for lattice extension GMK4080-2

Index

12

Index The index has the following structure: The names of the parts or assemblies you are searching for are listed in alphabetical sequence on the far left at the beginning of the line. The following are indented under these terms: – Activities (e.g. placing/removing the hoist rope) or – Subcategories (e.g. transport) or – Subcategories related to activities (e.g. swinging the lattice extension).

19.06.2019

H

The first search word is always a noun and is followed by an activity or a subcategory.

Operating instructions for lattice extension GMK4080-2

3 302 915 en

12 - 1

Index

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Blank page

12 - 2

3 302 915 en

Operating instructions for lattice extension GMK4080-2

19.06.2019

Index

A

Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1 description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5 attaching/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 reeving options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 installing/removing a folded auxiliary single-sheave boom top . . . . . . . . . 9 - 9 installing/removing the anemometer and air traffic control light . . . . . . . 9 - 14 installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12 moving the auxiliary single-sheave boom top into operating position . . . 9 - 5 moving the auxiliary single-sheave boom top into the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7 installing/removing the camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14 maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19 description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19 maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19 operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15 instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17 procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . 9 - 17 setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15 operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1 identification, slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1 transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2 transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2

B

Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1 checklists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7 CHECKLIST installing the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8 removing the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13 overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7 maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 35 maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 35 maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 35 maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 36 notes on this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1 operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31 derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 32 instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 33 procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . 6 - 33 setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31 operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5 transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6 transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6 rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19 section 3 – fitting/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 30 section 3 – folding out/folding in the deflection sheave . . . . . . . . . . . . . . . 6 - 19 section 3/main boom – establish/disconnect the connection . . . . . . . . . . . 6 - 20

Operating instructions for lattice extension GMK4080-2

3 302 915 en

12 - 3

Index

12 - 4

D

Driving with a rigged crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1 after driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15 before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15 driving path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2 permissible rigging modes and axle loads auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 14 boom extension 9.7 + 7.7 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8 heavy load lattice extension 1.8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12 heavy load lattice extension 2.0 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3 swing-away lattice 1.2 + 13.8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6 swing-away lattice 1.2 + 7.5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4 safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1 while driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15

H

Heavy load lattice extension 1.8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1 Checklists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 CHECKLIST Installing SLS 1.8 m - into the transport position . . . . . . . . . . . . . . . . . 8 - 13 Installing SLS 1.8 m - into the working position . . . . . . . . . . . . . . . . . . 8 - 10 Removing SLS 1.8 m - from the transport position . . . . . . . . . . . . . . . 8 - 18 Removing SLS 1.8 m - from the working position . . . . . . . . . . . . . . . . 8 - 15 Rigging SLS 1.8 m - into the transport position . . . . . . . . . . . . . . . . . . 8 - 23 Rigging SLS 1.8 m -into the working position . . . . . . . . . . . . . . . . . . . . 8 - 20 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 Description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27 Bringing section 6 from the transport position to the working position . . 8 - 30 Bringing section 6 from the working position to the transport position . . 8 - 32 Installing/removing the anemometer and air traffic control light . . . . . . . 8 - 45 Installing/removing the camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 46 Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 43 Installing/removing the shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 50 Installing/removing the sheaves package . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 48 Possible reeving methods on the heavy load lattice extension . . . . . . . . . 8 - 41 Section 6 – Fitting/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40 Section 6 – Setting the angle with a chain hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 38 with the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36 Section 6/Folding the rope attachment point . . . . . . . . . . . . . . . . . . . . . . . 8 - 35 Section 6/Main boom – Establishing/disconnecting the connection in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28

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Operating instructions for lattice extension GMK4080-2

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section 3/main boom – establish/disconnect the electrical connections . . 6 - 22 section 3/main boom – establish/disconnect the hydraulic connection . . 6 - 24 section 3/swing-away lattice – establish/disconnect the connection . . . . . 6 - 25 section 3/swing-away lattice – establish/disconnect the electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 27 section 3/swing-away lattice – establish/disconnect the hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29

19.06.2019

Index

Section 6/Main boom – Establishing/disconnecting the connection in the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 64 Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63 Maintenance plan M 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63 Operation with hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53 Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 56 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . 8 - 56 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53 Telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55 Operation with shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57 Derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 59 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . 8 - 62 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57 Telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61 Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6 Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5 Heavy load lattice extension 2.0 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Checklists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 CHECKLIST Installing SLS 2.0 m - into the transport position . . . . . . . . . . . . . . . . . 7 - 11 Installing SLS 2.0 m - into the working position . . . . . . . . . . . . . . . . . . . 7 - 8 Removing SLS 2.0 m - from the transport position . . . . . . . . . . . . . . . . 7 - 16 Removing SLS 2.0 m - from the working position . . . . . . . . . . . . . . . . 7 - 13 Rigging SLS 2.0 m - into the transport position . . . . . . . . . . . . . . . . . . 7 - 21 Rigging SLS 2.0 m -into the working position . . . . . . . . . . . . . . . . . . . . 7 - 18 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 Description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 Bringing section 5 from the transport position to the working position . . 7 - 28 Bringing section 5 from the working position to the transport position . . 7 - 30 Installing/removing the anemometer and air traffic control light . . . . . . . 7 - 41 Installing/removing the camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 42 Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39 Possible reeving methods on the heavy load lattice extension . . . . . . . . . 7 - 38 Section 5 – Fitting/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37 Section 5 – Setting the angle with a chain hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35 with the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33 Section 5/Folding the rope attachment point . . . . . . . . . . . . . . . . . . . . . . . 7 - 32 Section 5/Main boom – Establishing/disconnecting the connection in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26 Section 5/Main boom – Establishing/disconnecting the connection in the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50 Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49

Operating instructions for lattice extension GMK4080-2

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12 - 5

Index

12 - 6

L

Load turning, see Turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1

M

Main boom rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

O

Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 CCS control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 connection: section 1–main boom, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4 connection: section 1–main boom, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 connection: section 1–section 2, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4 connection: section 1–section 2, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 connection: section 2–main boom, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 connection: section 2–main boom, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7 on the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11 on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 other operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13 overview on the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 RCL control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 section 2 control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 Operating instructions basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 safety instructions for working with the lattice extension . . . . . . . . . . . . . . . . . 2 - 2 terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

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Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45 Derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 47 Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 48 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . 7 - 48 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45 Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4 Hose drum fitting/removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 hydraulic connections positions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6 positions when rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8 locking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 transport dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2 weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2

Index

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validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

P

Positions of the hydraulic connections during operation . . . . . . . . . . . . . . . . . . . . 4 - 6 Positions of the hydraulic connections when rigging . . . . . . . . . . . . . . . . . . . . . . . 4 - 8

R

Reeving options on the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 on the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 93 Rigging hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

S

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 for working with lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Swing-away lattice assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 attaching/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 91 checklist further rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 57 installing in operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17 installing in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 removing from the operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25 removing from transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 31 rigging the swing-away lattice 1.2 + 13.8 m in the operating position . . . 5 - 39 rigging the swing-away lattice 1.2 + 13.8 m in the transport position . . . . 5 - 51 rigging the swing-away lattice 1.2 + 7.5 m in the operating position . . . . 5 - 35 rigging the swing-away lattice 1.2 + 7.5 m in the transport position . . . . . 5 - 45 checklists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 110 derricking the swing-away lattice during rigging . . . . . . . . . . . . . . . . . . . . . . . 5 - 98 derricking the swing-away lattice in operation . . . . . . . . . . . . . . . . . . . . . . . . 5 - 111 description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 59 establish/disconnect the connection between section 1–section 2, left . . . . . 5 - 73 establish/disconnect the connection between section 1–section 2, right . . . . 5 - 75 establish/disconnect the connection between section 2–main boom, front . . 5 - 61 establishing/disconnecting electrical connections . . . . . . . . . . . . . . . . . . . . . . 5 - 84 establishing/disconnecting the hydraulic connection . . . . . . . . . . . . . 5 - 80, 5 - 82 finding and eliminating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 123 troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 123 folding deflection sheave in/out on section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 89 identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 installing/removing the air traffic control light . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 96 installing/removing the anemometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 96 installing/removing the camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 99 installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 94 main boom operation when the swing-away lattice is folded/rigged . . . . . . 5 - 114 maintenance

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Index

description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 118 maintenance plan M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 117 maintenance plan M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 118 maintenance plan M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 117 maintenance plan W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 117 maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 117 on this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 operating elements on the hand-held control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11 operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 overview of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 permissible combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 position of the telescoping cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 59 procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . . . 5 - 113 reeving options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 93 securing sections with a guide rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 60 setting the angle - with an auxiliary crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 102 setting the angle - without an auxiliary crane . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 103 slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 swinging operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 77 swinging section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 79 switching off the derricking gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 112 switching on the derricking gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 111 telescoping with rigged swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 111 transport condition, folded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11 transport condition, removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8 transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

Turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1

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Operating instructions for lattice extension GMK4080-2