Manitowoc Grove Crane GMK6300L-1 Lattice Extension Operation Manual

Lattice extension operating manual

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Important note Any type of duplication or excerpt from this document, also in electronic form, is not subject to the revision service of Manitowoc Crane Group Germany GmbH.

© Copyright reserved by

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

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Lattice extension operating manual GMK 6300L-1

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Manitowoc Crane Group Germany GmbH

These operating instructions contain the following chapters:

1 Overview 2 Basic safety instructions 3 For operations planning 4 Swing-away lattice 5 Boom extension 6 Auxiliary single-sheave boom top 7 Heavy load lattice extension 8 Turning loads 9 Driving with a rigged crane 10 Maintenance

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1 Overview

1.1

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

1

1.2

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

1

1.3

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

2

1.4

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

7

1.4.1 1.4.2 1.4.3 1.4.4

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

7 7 9 9

1.5

Conversion table for US measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10

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2 Basic safety instructions

2.1

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

1

2.2

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

1

2.3

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

2

2.4

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

2

2.5

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

3

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3 3

For operations planning

3.1

Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

1

3.2

Swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

3

3.2.1 3.2.2 3.2.3 3.2.4

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Transport dimensions, slinging points and weights . . . . . . . . . . . . . . . . . . . . . . 3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

3 4 5 7

3.3

Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

9

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11

3.4

Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

3.5

Heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15

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4 4

Swing-away lattice

4.1

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

1

4.1.2 4.1.3

Controls on the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Controls on the hand-held control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

4 5

4.2

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

7

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7

Overview of the required rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 CHECKLIST: Installing the 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . 4 - 8 CHECKLIST: Removing the 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . 4 - 10 CHECKLIST: Rigging the 12 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . 4 - 14 CHECKLIST: Rigging the 21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . 4 - 19 CHECKLIST: Unrigging 12 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25 CHECKLIST: Unrigging 21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29

4.3

Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 35

4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.3.9 4.3.10 4.3.11 4.3.12 4.3.13 4.3.14 4.3.15 4.3.16 4.3.17 4.3.18 4.3.19 4.3.20 4.3.21 4.3.22

To check whether the swing-away lattice is secured for transport . . . . . . . . . . 4 - 36 To move the swivel ram into the rigging/telescoping position . . . . . . . . . . . . . 4 - 40 Making/releasing the front connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 41 Making/releasing the rear connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 43 Derricking cylinder positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44 Position of the hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 45 Checking the locking device on the hose drum . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 47 Making/breaking the hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 48 Centre connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 49 Making/breaking section 1/section 2 connections . . . . . . . . . . . . . . . . . . . . . . . . 4 - 52 Connections on the left and right of the main boom head . . . . . . . . . . . . . . . . . 4 - 54 Making/breaking the slewing connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 57 To move the swivel ram into the rigging/telescoping position . . . . . . . . . . . . . 4 - 59 Swinging the swing-away lattice when rigging . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 61 Making/breaking connections to the swing-away lattice . . . . . . . . . . . . . . . . . . 4 - 65 Electrical connections to the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 68 Folding deflection sheaves out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 71 Positioning/removing the hoist rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 73 Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 76 Anemometer and air traffic control light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 79 Derricking the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 82

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4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8 4.5

Operation with swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 85 Setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . telescoping with rigged heavy load lattice extension . . . . . . . . . . . . . . . . . . . .

Derricking the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Information about the SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Notes on two-hook operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 - 85 4 - 87 4 - 88 4 - 89 4 - 91 4 - 91 4 - 92 4 - 93

Tracing and eliminating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 94

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5 Boom extension

5.1

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

1

5.1.1 5.1.2

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

1 6

5.2

Description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11

5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6

Installing/removing sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11 Installing/removing the swing-away lattice for the boom extension . . . . . . . . . 5 - 13 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14 Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17 Folding the deflection sheave in/out on section 3 and section 4 . . . . . . . . . . . . 5 - 20 Positioning/removing the hoist rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21

5.3

Operation with boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

Setting the SLI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23 Derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24 Telescoping with rigged boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25 Information about the SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26 Procedure if permissible wind speed is exceeded. . . . . . . . . . . . . . . . . . . . . . . . 5 - 26 Information about two-hook operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26

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6 Auxiliary single-sheave boom top

6.1

Installing/removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

1

6.1.1

Installing/removing the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . 6 -

1

6.2

Rigging the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

3

6.2.1 6.2.2 6.2.3

Rigging in working position/transport position . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Attaching and removing hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lifting limit switch and anemometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

3 4 5

6.3

Operation with the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . 6 -

7

6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6

Setting the SLI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Information about the SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . . . . . 6 SLI display with the auxiliary single-sheave boom top folded up/rigged . . . . . 6 Notes on two-hook operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

7 7 8 8 9 9

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7 7

Heavy load lattice extension

7.1

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

1

7.1.1 7.1.2 7.1.3 7.1.4

CHECKLIST: Installing the heavy load lattice extension . . . . . . . . . . . . . . . . . . . 7 CHECKLIST: Removing the heavy load lattice extension . . . . . . . . . . . . . . . . . . 7 CHECKLIST: Rigging the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . 7 CHECKLIST: Unrigging the heavy load lattice extension . . . . . . . . . . . . . . . . . . 7 -

1 2 3 5

7.2

Description of rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

7

Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 Fixing/releasing the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 Slewing the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9 To set the angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12 Positioning/removing the hoist rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14 Lifting limit switch and anemometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17

7.3

Operation with the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19

7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6

Setting the SLI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19 Derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20 Information about the SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . . . . . 7 - 21 SLI display with the heavy load lattice extension folded up/rigged . . . . . . . . . . 7 - 22 Notes on two-hook operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22

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8 Turning loads

8.1

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

1

8.2

Setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

2

8.3

Turning a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

4

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9 9

Driving with a rigged crane

9.1

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

1

9.2

Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

2

9.3

Rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

2

9.4

Before driving the rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

3

9.5

Driving the rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

3

9.6

Tables with boom positions and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

5

Swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6 Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8 Heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 Auxiliary single-sheave boom top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11

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10 Maintenance

10.1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

1

10.2

Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

2

10.3

Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -

3

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11 Index

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Overview 1.1 Accidents

1

Overview

1.1

Accidents In case of an accident, contact the Manitowoc Crane Care branch in country in GMK 6300L-1 operating manual the sections Acciwhich you are working; dents and Branches.

à

Adhere to the regulations regarding the duty of accident notification prevalent in the country in which you are working and inform the authorities who are in-charge of the monitoring and are responsible for that particular type of accident (e.g. material damage, injuries to persons).

1.2

Warranty

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You will find information about the warranty in the GMK 6300L-1 operating manual in the section Information about the warranty.

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1-1

Overview 1.3 Terms used

1.3

Terms used

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On the lattice extension

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Overview 1.3 Terms used

Swing-away lattice 1 Section 2 2 – Clamp for lifting limit switch 3 – Clamp for anemometer 4 – Connection section 1/section 2 5 Section 1 6 – Rear deflection sheave 7 – Derricking cylinders for setting the angle 8 – Switch unit 9 – Front deflection sheave 10 – Clamp for anemometer 11 – Fixed point for the hoist rope 12 – Clamp for lifting limit switch 13 – Sheave Boom extension 14 Section 4 15 Section 3 16 – deflection sheave 17 – Hydraulic hoses 18 – Electrical connecting cable 19 – deflection sheave 20 – Hydraulic hoses 21 – Electrical connecting cable Auxiliary single-sheave boom top 22 – Sheave 23 – Clamp for lifting limit switch Heavy load lattice extension 24 – Clamp for lifting limit switch 25 – Sheave 26 – Fixed point for the hoist rope

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1-3

Overview 1.3 Terms used

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On the main boom

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Overview 1.3 Terms used

1 – Hose drum 2 – Clamp for hydraulic hoses for main boom operation 3 – Hose guide 4 – Clamp for hydraulic hoses for working with the lattice extension 5 – Electrical connections 6 – Electrical connections 7 – Slewing connection 8 – Connections in the front area 9 – Support 10 – Connections in the centre area

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11 – Connections in the rear area

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1-5

Overview 1.3 Terms used

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Overview 1.4 Notes about the lattice extension operating manual

1.4

Notes about the lattice extension operating manual

1.4.1

What do the symbols used mean?

The signs and symbols used in this operating manual for especially important information can be found in the GMK 6300L-1 operating manual in the section Notes on the operating manual.

1.4.2

Definitions of direction information

Basic rule

Direction references always depend on whether the carrier or the superstructure is being operated.

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

2: right

3: rear

4: left

Forwards always means the driver's cab is to the front.

Reverse always means the rear lights on the carrier are to the front.

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1-7

Overview 1.4 Notes about the lattice extension operating manual

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

Switches and buttons

1: front

2: right

3: rear

4: left

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

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

General information on the operating elements

press (2) – opposite the symbol

Some switches are provided with a lock button.

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

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

– To switch off:

Information for display on buttons and symbols on the display GMK 6300L-1 operating manual section General rules for buttons and symbols.

à

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General rules for buttons and symbols

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

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Overview 1.4 Notes about the lattice extension operating manual

1.4.3

How are the operating instructions structured?

Chapter 1 contains an overview of the lattice extensions.

Chapter 2 contains information about the safety requirements.

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

In chapter 4 and the following chapters, rigging and operation of lattice extensions is described.

Chapter 8 gives information on turning loads over, using lattice extensions.

In chapter 9 you will find how to drive a rigged crane on construction sites.

Chapter 10 describes the maintenance of lattice extensions.

Chapter 11 contains the index.

G 1.4.4

Risk of accidents when only referring to the checklists during operation!

The checklists and operating instructions should always be regarded as a single unit for the complete description of a rigging procedure.

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

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

How do I find the information I need?

The operating instructions contain the following guides for orientation.

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

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

– The index in chapter 11 gives an alphabetic list of keywords and search terms with a reference to the relevant page in the operating instructions.

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à

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

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

You will find an example of the use of cross references in the GMK 6300L1 operating manual.

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1-9

Overview 1.5 Conversion table for US measurements

1.5

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

Multiply by

mm

in

0.03937

in

mm

25.4

m

ft

3.28084

ft

m

0.30479

m²

ft²

10.76391

cm²

in²

0.155

cm³

in³

0.061

l

gal (US)

0.264178

kg

lbs

2.204622

lbs

kg

0.45359

t

lbs

2204.622

lbs

t

0.0004536

kN

lbf

224.809

daN/cm²

lbf/in²

14.50378

lbf/in²

daN/cm²

0.06895

bar

psi

14.50378

psi

bar

0.06895

m/s

ft/s

3.28084

km/h or km

mph or mi

0.62137

mph or mi

km/h or km

1.60935

Nm

ft lbf

0.7375

°C

°F

1.8 x °C + 32

°F

°C

(°F-32)/1.8

t/m²

lbs/ft²

204.8

m²/t

ft²/lbs

0.04882 12.03.2018

Converting from

1 - 10

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Lattice extension operating manual GMK 6300L-1

Basic safety instructions 2.1 Intended use

2

Basic safety instructions In principle, the basic safety instructions apply from the GMK 6300L-1 operating manual. The basic safety instructions for the lattice extensions supplied for the truck crane are given below.

H 2.1

Information regarding the used warnings and symbols; operating manual.

à GMK 6300L-1

Intended use The GMK 6300L-1 is a state-of-the-art truck crane, designed in accordance with approved safety regulations. Nevertheless, the operator or third parties can still be endangered and the crane or other property put at risk while using it.

H 2.2

In addition to the following specifications, also observe the specifications for intended use in the GMK 6300L-1 operating manual.

The GMK 6300L-1 may only be operated with parts of equipment which are permitted by Manitowoc Crane Group Germany GmbH and which are labelled with the serial number of the GMK 6300L-1.

Improper use Manitowoc Crane Group Germany GmbH is not liable for damage resulting from the improper or unauthorized use of the GMK 6300L-1 truck crane. The user alone bears the risk.

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H

In addition to the following specifications, also observe the specifications for improper use in the GMK 6300L-1 operating manual.

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2-1

Basic safety instructions 2.3 Organisational measures

2.3

Organisational measures

H

In addition to the following specifications, also observe the organisational measures in the GMK 6300L-1 operating manual and in the Maintenance manual.

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

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

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

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

Observe all safety instructions and warnings on the truck crane.

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

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

2.4

Personnel qualifications

Requirements

These operating instructions are not a training manual for beginners.

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

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

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

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

The prerequisites which you, as crane operator, must fulfil are described in the GMK 6300L-1 operating manual and in the Safety manual.

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

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

Training courses

Manitowoc Crane Group Germany GmbH conducts general and type-specific crane operator courses and technical courses; GMK 6300L-1 operating manual Training information section.

2.5

Safety instructions for working with the lattice extension

à

The operation of GMK 6300L-1 with one of the lattice extensions described in these operating instructions is subject to: – all the safety instructions contained in the operating instructions supplied with the GMK 6300L-1 and – all the following safety instructions.

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

Walk only on those machine parts which are equipped with appropriate platforms and railings and therefore guarantee safety. During rigging and maintenance work on machine parts above body height which have no device for accessing them, always use the extendable ladder supplied (e.g. when reeving the hoist rope on the boom head).

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

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

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

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2-3

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

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

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

Lifting loads simultaneously with two cranes is particularly dangerous.

Carry out this type of work with special care.

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

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

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

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

When the swing-away lattice is folded onto the main boom for transport, it must be secured in the slewing connection with a pin.

Otherwise the swing-away lattice can swing out by itself if the hydraulics of the swivel ram is damaged.

If this happens, the permissible vehicle will be exceeded.

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

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For operations planning 3.1 Information

3

For operations planning

3.1

Information The following section gives information on the topics of: – assembly, – identification, – transport dimensions and weights, – slinging points and – transport.

assembly

The lengths in each case are given as the distance between the centre of the locking pin (on the main boom head) and the front edge of the head sheave.

For this reason, the lengths of the individual parts given in the sections transport dimensions and weights and their totals do not agree with the lengths stated here.

Identification

S Transport dimensions and weights

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

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

Adjustments to the lattice extension may only be carried out by Manitowoc Crane Care.

This prevents malfunctions and damage.

Take note of the data on the weight and dimensions of the lattice extension in the respective sections. The dimensions listed here, and their totals, do not agree with the data listed in the Assembly section.

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3-1

For operations planning 3.1 Information

Slinging points

G

Danger of accidents if used improperly!

Only fit slings to the lattice extension at the slinging points provided. Only use lifting gear and joining elements of sufficient load bearing capacity.

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

Transport

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S

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

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For operations planning 3.2 Swing-away lattice

3.2

Swing-away lattice

3.2.1

Assembly Observe the instructions on assembly and Identification;

Designation

à p. 3 - 1.

Assembly Section 1 (1) ●

B 21 m swing-away lattice

●

●

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A 12 m swing-away lattice

Section 2 (2)

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3-3

For operations planning 3.2 Swing-away lattice

3.2.2

Identification Observe the instructions regarding Identificap. 3 - 1. tion;

à

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In order to identify the parts of the swing-away lattice, they are marked with the serial number (1) of the truck crane.

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For operations planning 3.2 Swing-away lattice

3.2.3

Transport dimensions, slinging points and weights Observe the instructions regarding Slinging points;

à p. 3 - 2.

Slinging type

• Slinging is to be performed for the respective rigging mode as shown in the illustration.

(A)

21 m swing-away lattice, section 2 swung out

(B)

21 m swing-away lattice, section 2 folded

(C)

12 m swing-away lattice

(D)

Only section 2

For (D), the following applies:

• Always raise the swing-away lattice with two single lines.

• Raise the swing-away lattice a little first and check whether it hangs horizontally.

• Reposition the slinging points if necessary.

The slinging points can be seen in the following illustration.

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3-5

For operations planning 3.2 Swing-away lattice

Slinging points

A

B

C

D

Designation

Length x width x height in m

Weight in kg

Slinging points

21 m swing-away lattice, section 2 swung out

21.7 x 1.1 x 1.5

2 100

(4) and (5)

B

21 m swing-away lattice, section 2 folded

12.7 x 1.1 x 1.5

2 100

(2) and (3)

C

12 m swing-away lattice

12.7 x 1.1 x 1.5

1 600

(1) and (2)

D

Only section 2

9.1 x 0.6 x 0.8

500

(6) and (7)

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A

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For operations planning 3.2 Swing-away lattice

3.2.4

Transport Observe the instructions regarding Transport;

à p. 3 - 2.

• Check whether all the required connections for transport condition are established; Securing the swing-away lattice for transport when removed, p. 4 - 37.

à

• Put the swing-away lattice onto the skids for transport (1).

• Always secure the lattice extension on the

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transport vehicle with belts to prevent slipping and overturning.

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3-7

For operations planning 3.2 Swing-away lattice

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For operations planning 3.3 Boom extension

3.3

Boom extension

3.3.1

Assembly Observe the instructions on assembly and Identification;

Designation

à p. 3 - 1.

Assembly Section 2 (2)

Section 3 (3)

A 29 m boom extension

●

●

●

B 37 m boom extension

●

●

●

Section 4 (4) ●

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Section 1 (1)

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3-9

For operations planning 3.3 Boom extension

3.3.2

Identification Observe the instructions regarding Identification;

à p. 3 - 1.

In order to identify the parts, they are marked with the serial number (1) of the truck crane.

3.3.3

Transport dimensions and weights

Designation

Length x width x height in m

Weight in kg

8.2 x 0.9 x 1.2

675

Section 3 (with foldedin deflection sheave)

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Section 4 (with foldedin deflection sheave)

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For operations planning 3.3 Boom extension

3.3.4

Slinging points Observe the instructions regarding Slinging points;

à p. 3 - 2.

The sections have two slinging points (1).

3.3.5

Transportation Observe the instructions regarding Transport;

à p. 3 - 2.

• Place the parts for transport onto supports (1) in the front and rear.

• Always secure the lattice extension on the

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transport vehicle with belts to prevent slipping and overturning.

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3 - 11

For operations planning 3.3 Boom extension

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For operations planning 3.4 Auxiliary single-sheave boom top

3.4

Auxiliary single-sheave boom top

Identification and slinging point

Observe the instructions regarding: p. 3 - 1.

– Identification; – Slinging points; p. 3 - 2.

à à

In order to identify the auxiliary single-sheave boom top, it is marked with the serial number (1) of the truck crane.

• Attach a sling strap. Be careful not to damage any additional units.

Transport dimensions and weight

Designation

Weight in kg

0.8 x 0.4 x 1.1

80

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Auxiliary single-sheave boom top

Length x width x height in m

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3 - 13

For operations planning 3.4 Auxiliary single-sheave boom top

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For operations planning 3.5 Heavy load lattice extension

3.5

Heavy load lattice extension

Identification and slinging point

Observe the instructions regarding: p. 3 - 1 and – Identification; – Slinging points; p. 3 - 2.

à à

In order to identify the heavy load lattice extension, it is marked with the serial number (1) of the truck crane.

• Attach the sling gear with suitable joining elements at the slinging points (2).

Transport dimensions and weight

Length x width x height in m

Weight in kg

Heavy load lattice extension

2.2 x 1.1 x 1.2

750

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Designation

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3 - 15

For operations planning 3.5 Heavy load lattice extension

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Swing-away lattice 4.1 Short description of the operating elements

4

Swing-away lattice The swing-away lattice is also a part of the boom extension. For this reason, the descriptions here also refer to the boom extension under certain conditions.

Then, instead of the expression swing-away lattice, the collective term lattice extension is used.

H

The lifting capacity tables primarily contain the term swing-away lattice extension. This term will only be used later in this chapter, when a length specification is necessary.

When no length data is necessary (e.g. for rigging work), the term swingaway lattice is only used when the text needs to be as short as possible.

4.1

Short description of the operating elements

4.1.1

In the crane cab

At the control console, right Derricking gear of lattice extension on/off There is a lamp in the button.

– Press once

– Lamp bright – derricking gear on, power units with the same control lever configuration off – Lamp dim – derricking gear off

à p. 4 - 89 Right control lever – To the left:

Raise – lift swing-away lattice

– To the right:

Lower – lower swing-away lattice

à p. 4 - 89

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4-1

Swing-away lattice 4.1 Short description of the operating elements

On the crane control display Power unit display – in main menu – Green:

Derricking gear on

– Red:

Derricking gear off

Display of position of swing-away lattice – in the telescope submenu – Off:

Retracting/extending enabled

– Red:

Retracting/extending disabled

Limiting power unit speed – power unit speed submenu If the symbol (1) in shown in black, a maximum speed can be set for the derricking gear of the lattice extension; GMK 6300L-1 operating manual.

à

Display operating hours – operating hours submenu The operating hours of the derricking gear of the lattice extension are displayed under the symbol (1); GMK 6300L-1 operating manual.

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à

4-2

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Lattice extension operating manual GMK 6300L-1

Swing-away lattice 4.1 Short description of the operating elements

On the safe load indicator

Enter the SLI code for operation with lattice extension according to the load capacity chart, as described in the GMK 6300L-1 operating manual.

Enter the components of the lattice extension as described in the following.

Boom system entry – Input mode on:

– For boom system: Press button (3) until symbol (2) is green – For length and angle of lattice extension1): Press button (3) until symbol (1) is green

– Input:

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

à GMK 6300L-1 operating manual 1)

Lattice extension – inclinable

Boom system display Boom system for displayed SLI code, 1 Main boom/auxiliary single-sheave boom top 2 Lattice extension 2.1 Length 2.2 Angle1) 3 SLI rigging code for angling entered1) 4 Heavy load lattice extension

à GMK 6300L-1 operating manual 1)

Lattice extension – inclinable

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4-3

Swing-away lattice 4.1 Short description of the operating elements

In the monitoring submenu, the following are shown for the lattice extension: 1 The current angle of the lattice extension 2 The length of the rigged lattice extension

4.1.2

Controls on the swing-away lattice

1 Raise swing-away lattice 2 Lower swing-away lattice 3 Dead man's switch

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

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Swing-away lattice 4.1 Short description of the operating elements

4.1.3

Controls on the hand-held control unit This section is only valid for the derricking swing-away lattice.

The button (1) derrick lattice extension is active if the swing-away lattice is electrically connected.

Pre-select and then press the required combination of buttons.

– Pre-selection on:

Press button once – lamp (1) lights up – pre-selection on until another pre-selection is made

– Pre-selection off:

Press a non-allocated combination of buttons

– Pre-selected function on

Press the required button combination

– Pre-selected function off

Release one or both the buttons

– Extend swivel ram:

Press shown button combination

– Retract swivel ram:

Press button combination shown

– Raise swing-away lattice:

Press button combination shown

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4-5

Swing-away lattice 4.1 Short description of the operating elements

Press button combination shown

– Faster movement:

Press the button harder

– Slower movements:

Press the button less hard

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– Lower the swing-away lattice:

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Swing-away lattice 4.2 Checklists for rigging work

4.2

Checklists for rigging work

4.2.1

Overview of the required rigging work There are different initial states for rigging the swing-away lattice, depending on whether the swing-away lattice is: – folded at the side of the main boom or – dismantled for on-road driving.

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

Before the crane operation

– Folded at the side of the main boom

Rig the 12 m swing-away lattice;

– Completely dismantled

Installation;

– Must be folded at the side of the main boom

Unrig the 12 m swing-away latp. 4 - 25, tice;

à p. 4 - 14,

Rig the 21 m swing-away lattice;

à p. 4 - 19.

à p. 4 - 8.

à

Unrig the 21 m swing-away lattice; p. 4 - 19.

à

– Must be removed for onroad driving

Driving mode specifications

Removal1);

à p. 4 - 10.

à Operating instructions – Driving modes.

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1)

Associated checklist for ...

After the crane operation

Starting position of the swing-away lattice

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4-7

Swing-away lattice 4.2 Checklists for rigging work

4.2.2

CHECKLIST: Installing the 12/21 m swing-away lattice

H

This checklist is not equivalent to the complete operating instructions.

There are accompanying operating instructions which are referred to by cross-references.

Observe the warnings and safety instructions specified there!

Requirements: – The truck crane is on outriggers or the main boom has been placed on the boom rest.

– An auxiliary crane is available.

– The hose drum has been installed; GMK 6300L-1 operating manual.

à

1. Check whether the swing-away lattice is secured for transport; Securing the swing-away lattice for transport when removed, p. 4 - 37.

à

1. Check that the locking device has been released;

à p. 4 - 47.

2. Attach sling to the swing-away lattice and attach guide ropes. To attach p. 3 - 5. sling to the swing-away lattice;

à

à To make

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3. Lift the swing-away lattice and make slewing connection; the connection, p. 4 - 57.

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Swing-away lattice 4.2 Checklists for rigging work

G

Risk of crushing due to movement of swing-away lattice Always secure the swing-away lattice with the guide ropes to prevent it from swinging before you make the hydraulic or electrical connections.

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

4. Make the hydraulic/electrical connections; Making the hydraulic connection, p. 4 - 48, Making an electrical connection, p. 4 - 68.

à à

5. For further folding of: 12 m swing-away lattice: CHECKLIST: Unrigging 12 m swing-away latp. 4 - 26. tice from point 8.

à

21 m swing-away lattice: CHECKLIST: Unrigging 21 m swing-away latp. 4 - 31. tice from point 15.

à

6. For further rigging of: 12 m swing-away lattice: CHECKLIST: Rigging the 12 m swing-away p. 4 - 16. lattice from point 13.

à

21 m swing-away lattice: CHECKLIST: Rigging the 21 m swing-away p. 4 - 21. lattice from point 14.

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Swing-away lattice 4.2 Checklists for rigging work

4.2.3

CHECKLIST: Removing the 12/21 m swing-away lattice

H

This checklist is not equivalent to the complete operating instructions.

There are accompanying operating instructions which are referred to by cross-references.

Observe the warnings and safety instructions specified there!

Requirements: – The truck crane is on outriggers or the main boom has been placed on the boom rest.

– An auxiliary crane is available.

For rigged swingaway lattice

H

This checklist only applies when the swing-away lattice is rigged. If the If swing-away lattice is swung away, p. 4 - 12. swing-away lattice is folded;

à

If the swing-away lattice should be transported in its folded state: 1. Unrig swing-away lattice

à CHECKLIST: Unrigging 12 m swing-away lattice, p. 4 - 25 or à CHECKLIST: Unrigging 21 m swing-away lattice, p. 4 - 29.

2. Remove swing-away lattice

à If swing-away lattice is swung away, p. 4 - 12

1. All rigging work should be carried out according to the points in the specified checklist.

12 m swing-away lattice: CHECKLIST: Unrigging 12 m swing-away lattice up to and including point 9. p. 4 - 26.

à

21 m swing-away lattice: CHECKLIST: Unrigging 21 m swing-away lattice up to and including point 17. p. 4 - 31.

à

2. Disconnect the hydraulic/electrical connections: Disconnecting the hydraulic connection, p. 4 - 48, Disconnecting the electrical connection, p. 4 - 69.

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à à

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Swing-away lattice 4.2 Checklists for rigging work

3. Attach auxiliary crane sling to the swing-away lattice and attach guide rope. To attach sling to the swing-away lattice; p. 3 - 5.

à

4. Release the connections on the right and left of the main boom head; Releasing connections, p. 4 - 55.

à

5. If section 2 is to be removed from the main boom: – Fit sling from the auxiliary crane to section 2;

à p. 3 - 5.

– Move the connection in the Middle area into the position Section2/main p. 4 - 50. boom;

à

– Release the rear connection;

à p. 4 - 43.

– Set down section 2 on the separate vehicle.

6. Check whether the swing-away lattice is secured for transport; Securing the swing-away lattice for transport when removed, p. 4 - 37.

à

7. Position hydraulic hoses ready for work with the main boom; p. 4 - 46.

à

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Swing-away lattice 4.2 Checklists for rigging work

If swing-away lattice is swung away

This checklist only applies when the swing-away lattice is swung away. If the swing-away lattice is rigged; For rigged swing-away lattice, p. 4 - 10.

à

1. Disconnect the hydraulic/electrical connections: Disconnecting the hydraulic connection, p. 4 - 48, Disconnecting the electrical connection, p. 4 - 69.

à à

2. Attach auxiliary crane sling to the swing-away lattice and attach guide rope. To attach sling to the swing-away lattice p. 3 - 5.

à

3.

– Check whether the connection between section 1 and section 2 has been made; p. 4 - 52.

– Check that the connection in the middle area is in the position section 1/section 2; p. 4 - 49.

à

à

4.

à p. 4 - 43. à p. 4 - 42.

– Release the rear connection; – Release the front connection;

5. Set down swing-away lattice on the separate vehicle; p. 3 - 7.

à Transport,

6. Check whether the swing-away lattice is secured for transport; Securing the swing-away lattice for transport when removed, p. 4 - 37.

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à

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Swing-away lattice 4.2 Checklists for rigging work

7. Position hydraulic hoses ready for work with the main boom; p. 4 - 46.

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Swing-away lattice 4.2 Checklists for rigging work

4.2.4

CHECKLIST: Rigging the 12 m swing-away lattice

H

This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by cross-references. Observe the warnings and safety instructions there.

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

à Operating

– Before crane operation, check according to CHECKLIST: Checks before crane operation; Operating manual.

à

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

– Roll the unused hoist rope on to drum.

2. Connect the hand-held control unit; p. 4 - 82.

à With the hand-held control,

3. Check whether the swing-away lattice is secured for transport; Securing for transport when the swing-away lattice is swung around, p. 4 - 38.

à

4. Position hydraulic hoses ready for working with the lattice extension; p. 4 - 45.

à

5. Make the hydraulic/electrical connections; Making the hydraulic connection, p. 4 - 48, Making an electrical connection, p. 4 - 68.

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à à

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Swing-away lattice 4.2 Checklists for rigging work

6. Secure the swing-away lattice with guide rope;

à p. 4 - 35.

7. Move the connection in the Middle area into the position Section 2/Main boom; p. 4 - 50.

à

8. Move the swivel ram into the rigging position;

9. Make a slewing connection;

à p. 4 - 59.

à p. 4 - 57.

10. Release the connection between section 2 and section 1;

à p. 4 - 52.

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Swing-away lattice 4.2 Checklists for rigging work

11. Move the swivel ram into the telescope position;

à p. 4 - 60.

If necessary derrick the swing-away lattice to take the load off of the connection between section 2 and section 1.

12. Release the Front connection;

à p. 4 - 42.

13. Swing the swing-away lattice in front of the main boom head; When rigging – section 1, p. 4 - 61.

à

14. Make the connections on the right and left of the main boom head; Making connections, p. 4 - 54.

à

15. Fold out the deflection sheaves to the front and rear;

à p. 4 - 74.

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16. Put the hoist rope on the swing-away lattice;

à p. 4 - 71.

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Swing-away lattice 4.2 Checklists for rigging work

17. Install the anemometer and if necessary make an electrical connection for the air traffic control light; Installing, p. 4 - 79.

à

18. Reeve the hoist rope on the hook block; manual.

à GMK 6300L-1 operating

19. Attach the lifting limit switch, fit the lifting limit switch weight and place it around the hoist rope; GMK 6300L-1 operating manual.

à

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

21. Disconnect the hand-held control unit; ual.

à GMK 6300L-1 operating man-

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Swing-away lattice 4.2 Checklists for rigging work

22. Enter the current rigging mode with the rigged swing-away lattice; Setting the SLI, p. 4 - 85.

à

23. Enter current reeving;

à Setting the SLI, p. 4 - 85.

Further steps with swing-away lattice:

à

p. 4 - 87.

– Raise main boom; – Telescope main boom; p. 4 - 88.

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à

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Swing-away lattice 4.2 Checklists for rigging work

4.2.5

CHECKLIST: Rigging the 21 m swing-away lattice

H

This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by cross-references. Observe the warnings and safety instructions there.

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

à Operating

– Before crane operation, check according to CHECKLIST: Checks before Operating manual. crane operation;

à

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

– Roll the unused hoist rope on to drum.

2. Check whether the swing-away lattice is secured for transport; Securing for transport when the swing-away lattice is swung around, p. 4 - 38.

à

3. Connect the hand-held control unit; p. 4 - 82.

à With the hand-held control,

4. Position hydraulic hoses ready for working with the lattice extension; p. 4 - 45.

à

5. Make the hydraulic/electrical connections; Making the hydraulic connection, p. 4 - 48, Making an electrical connection, p. 4 - 68.

à à

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Swing-away lattice 4.2 Checklists for rigging work

6. Secure the swing-away lattice with guide rope;

à p. 4 - 35.

7. Check, – whether the connection in the middle area is in the position section 1/ p. 4 - 49. section 2; – whether the connection between section 1 and section 2 has been p. 4 - 52. made;

à

à

8. Move the swivel ram into the rigging position;

9. Make a swivelling connection;

10. Release the rear connection;

à p. 4 - 59.

à p. 4 - 57.

à p. 4 - 43.

à p. 4 - 44.

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11. Move the derricking cylinder to position 1;

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Swing-away lattice 4.2 Checklists for rigging work

12. Move the swivel ram into the telescope position;

13. Release the Front connection;

à p. 4 - 60.

à p. 4 - 42.

14. Swing the swing-away lattice in front of the main boom head; When rigging – section 1, p. 4 - 61.

à

15. Make the connections on the right and left of the main boom head; Making connections, p. 4 - 54.

à

16. If section 2 is transported on a separate vehicle, install section 2 in front of section 1: – Sling section 2; p. 3 - 5. p. 4 - 66.

– Raise section 2 in front of section 1 and lock it there; – After installing section 2, proceed as from point 22.

à

à

17. If section 2 is folded on section 1, fasten a guide rope to section 2.

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Swing-away lattice 4.2 Checklists for rigging work

18. Move the Middle connection into the Section 1 position;

19. Swing section 2 in front of section 1; p. 4 - 62.

à p. 4 - 51.

à When rigging – section 2,

20. Make the connection on the left between section 2 and section 1; Section 1 and section 2 fitted, p. 4 - 65.

à

21. Make the electrical connection;

à p. 4 - 69.

22. Fold out the deflection sheaves to the front and rear;

à p. 4 - 74.

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23. Put the hoist rope on the swing-away lattice;

à p. 4 - 71.

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Swing-away lattice 4.2 Checklists for rigging work

24. Install the anemometer and if necessary make an electrical connection for the air traffic control light; Installing, p. 4 - 79.

à

25. Reeve the hoist rope on the hook block; manual.

à GMK 6300L-1 operating

26. Attach the lifting limit switch, fit the lifting limit switch weight and place it around the hoist rope; GMK 6300L-1 operating manual.

à

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

28. Disconnect the hand-held control unit; ual.

à GMK 6300L-1 operating man-

29. Enter the current rigging mode with the rigged swing-away lattice; Setting the SLI, p. 4 - 85.

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à

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Swing-away lattice 4.2 Checklists for rigging work

30. Enter current reeving;

à Setting the SLI, p. 4 - 85.

Further steps with swing-away lattice:

à

p. 4 - 87.

– Raise main boom; – Telescope main boom; p. 4 - 88.

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à

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Swing-away lattice 4.2 Checklists for rigging work

4.2.6

CHECKLIST: Unrigging 12 m swing-away lattice

H

This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by cross-references. Observe the warnings and safety instructions there.

1. Retract the main boom completely; lattice extension, p. 4 - 88.

2.

à telescoping with rigged heavy load

à

– Completely raise the swing-away lattice; p. 4 - 89.

– Lower the main boom to the horizontal position; p. 4 - 87.

à

3. Remove the lifting limit switch weight and remove the lifting limit switch; Installing/removing the lifting limit switch, p. 4 - 76.

à

4. If necessary, disconnect the electrical connection of the air traffic conRemoving, p. 4 - 80. trol light and remove the anemometer;

à

5. Connect the hand-held control unit; p. 4 - 82.

à With the hand-held control,

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Swing-away lattice 4.2 Checklists for rigging work

6. Unreeve the hoist rope from the swing-away lattice and reel it up to the main boom head; p. 4 - 73.

à

7. Fold in the deflection sheaves at the front and rear;

8. Move the swivel ram into the telescope position;

à p. 4 - 72.

à p. 4 - 60.

9. Fasten a guide rope to section 1.

10. Check that a slewing connection has been made.

If necessary make a slewing connection;

à p. 4 - 57.

11. Release the connections on the right and left of the main boom head; Releasing connections, p. 4 - 55.

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à

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Swing-away lattice 4.2 Checklists for rigging work

12. Slew the swing-away lattice to the Front connection; – section 1, p. 4 - 62.

13. Make the Front connection;

à When unrigging

à To make the connection, p. 4 - 41.

14. Move the derricking cylinder to position 3; tions, p. 4 - 44.

à Derricking cylinder posi-

à

p. 4 - 59.

15. Move the swivel ram into the rigging position; Use the derricking cylinder to correct the position of section 1 so that section 1 and section 2 are aligned.

à

16. Make the connection between section 1 and section 2; p. 4 - 52.

– Move the Middle connection into the position section 1/section 2; p. 4 - 49.

à

17. Undo the slewing connection;

à p. 4 - 58.

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Swing-away lattice 4.2 Checklists for rigging work

18. Disconnect the hydraulic/electrical connections: Disconnecting the hydraulic connection, p. 4 - 48, Disconnecting the electrical connection, p. 4 - 69.

à à

19. Position hydraulic hoses ready for work with the main boom; p. 4 - 46.

à

20. Disconnect the hand-held control unit; ual.

à GMK 6300L-1 operating man-

21. Check whether the swing-away lattice is secured for transport; Securing for transport when the swing-away lattice is swung around, p. 4 - 38.

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à

4 - 28

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Swing-away lattice 4.2 Checklists for rigging work

4.2.7

CHECKLIST: Unrigging 21 m swing-away lattice

H

This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by cross-references. Observe the warnings and safety instructions there.

1. Retract the main boom completely; lattice extension, p. 4 - 88.

2.

à telescoping with rigged heavy load

à

– Completely raise the swing-away lattice; p. 4 - 89.

– Lower the main boom to the horizontal position; p. 4 - 87.

à

3. Remove the lifting limit switch weight and remove the lifting limit switch; Installing/removing the lifting limit switch, p. 4 - 76.

à

4. If necessary, disconnect the electrical connection of the air traffic conRemoving, p. 4 - 80. trol light and remove the anemometer;

à

5. Connect the hand-held control unit; p. 4 - 82.

à With the hand-held control,

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Swing-away lattice 4.2 Checklists for rigging work

6. Unreeve the hoist rope from the swing-away lattice and reel it up to the main boom head; p. 4 - 73.

à

7. Fold in the deflection sheaves at the front and rear;

8. Move the swivel ram into the telescope position;

à p. 4 - 72.

à p. 4 - 60.

9. Fasten a guide rope to section 2.

10. Check whether the a slewing connection has been made between section 1 and section 2. If necessary make a slewing connection; p. 4 - 52.

à

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11. Disconnect the electrical connection; p. 4 - 70.

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Swing-away lattice 4.2 Checklists for rigging work

12. If section 2 is to be removed:

à

– Fit sling from the auxiliary crane to section 2; p. 3 - 5.

– Release the connection between section 2 and section 1; p. 4 - 66.

– Set down section 2 on the separate vehicle.

– After removing section 2, proceed as from point 15.

à

13. Disconnect the connection on the left between section 2 and section 1; p. 4 - 65.

à

14. Swing section 2 next to section 1 and move the middle connection into Section 1/Section 2 position; When unrigging – section 2, p. 4 - 64, Section 1/section 2 position, p. 4 - 49.

à à

15. Fasten a guide rope to section 1.

16. Check that a slewing connection has been made. If necessary make a slewing connection; p. 4 - 57.

à

17. Release the connections on the right and left of the main boom head; Releasing connections, p. 4 - 55.

à

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Swing-away lattice 4.2 Checklists for rigging work

18. Swing the swing-away lattice against the side of the main boom; When unrigging – section 1, p. 4 - 62.

à

19. Make the Front connection;

à p. 4 - 41.

20. Move the derricking cylinder to position 3;

à p. 4 - 44.

21. Move the swivel ram into the rigging position;

22. Release the rear connection;

à p. 4 - 59.

à p. 4 - 43.

Move the derricking cylinder to position 2;

à p. 4 - 58.

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23. Undo the slewing connection;

à p. 4 - 44.

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Swing-away lattice 4.2 Checklists for rigging work

24. Disconnect the hydraulic/electrical connections: Disconnecting the hydraulic connection, p. 4 - 48, Disconnecting the electrical connection, p. 4 - 69.

à à

25. Position hydraulic hoses ready for work with the main boom; p. 4 - 46.

à

26. Disconnect the hand-held control unit; ual.

à GMK 6300L-1 operating man-

27. Check whether the swing-away lattice is secured for transport; Securing for transport when the swing-away lattice is swung around, p. 4 - 38.

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à

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Swing-away lattice 4.2 Checklists for rigging work

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4 - 34

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Swing-away lattice 4.3 Description of rigging work

4.3

Description of rigging work

4.3.1

Securing the swing-away lattice with a rope For certain alignments of the truck crane, the swing-away lattice can swing around by itself when the last connection to the main boom is removed.

G

There is a risk of accidents due to the swing-away lattice swinging of its own accord.

Always secure the swing-away lattice with a guide rope on the main boom before disconnecting anything.

This will prevent the swing-away lattice from swinging around of its own accord and pushing you off the crane base or causing injury to you or other persons.

Secure the swing-away lattice in the following manner:

• Attach a rope (2) at the front of the swingaway lattice.

• Guide the rope underneath the swing-away lattice, over the rope guide (1) on the main boom and back again.

• Have a helper hold the rope tight while you are releasing the last connection.

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H

If you are alone, secure the other end of the cord on the crane (depending on the slewing direction of the superstructure, e.g. on the rear right on the outrigger beam or on the left on the steps of the access ladder to the carrier).

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Swing-away lattice 4.3 Description of rigging work

4.3.2

To check whether the swing-away lattice is secured for transport For transport, certain connections must be made between the sections of the swing-away lattice, depending on whether the swing-away lattice: – is folded up against the main boom for transport or – is removed for transportation.

S G

There is a risk of damage to the lattice and the main boom.

Always secure the swing-away lattice for transport before driving the truck crane with a folded swing-away lattice or working with the main boom.

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

This way you prevent 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.

Risk of accidents if the permissible vehicle is exceeded.

When the swing-away lattice is folded onto the main boom for transport, it must be secured in the slewing connection with a pin.

Otherwise the swing-away lattice can swing out by itself if the hydraulics of the swivel ram is damaged.

If this happens, the permissible vehicle will be exceeded.

Check that the swing-away lattice is secured for transport: – After unrigging the swing-away lattice, before you drive the truck crane or work with the main boom.

– After unrigging the swing-away lattice, regardless of whether you drive the truck crane, work with the main boom or whether the swing-away lattice has been removed.

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– Before installation and before rigging the swing-away lattice.

The corresponding checklists require that the swing-away lattice be secured for transport.

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Swing-away lattice 4.3 Description of rigging work

Securing the swing-away lattice for transport when removed

It is secured for transport when all of the following connections have been made.

• Check the following connections and make them if necessary.

– Check whether the connection (2) between section 1 and section 2 has p. 4 - 49. been made; The unneeded pins (1) are secured in the retaining sheet.

à

– In the middle connection (3) is in position section 1/section 2;

à p. 4 - 49.

– At the rear connection, the lever (4) is horizontal.

– The lever (4) for the connection at the rear side is in position A; p. 4 - 43.

à

– The pins (5) and (6) on section 1 are secured with retaining pins.

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Swing-away lattice 4.3 Description of rigging work

Securing for transport when the swing-away lattice is swung around

It is secured for transport when all of the following connections have been made.

For folded swing-away lattice, the axle load is over 12 t.

Check the connections and make them if necessary.

If section 1 and section 2 are folded onto the main boom: – The middle connection (4) is in position section 1/section 2;

à p. 4 - 49.

– The connection at the rear is established (lever (2) in position A); p. 4 - 43.

à

à

– The part 1/part 2 connection (3) has been made; p. 4 - 49.

The unneeded pins (1) have been secured in the holder.

à p. 4 - 41.

– Swivel ram (6) is in the rigging position; à p. 4 - 59.

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– The front connection (5) has been made;

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Swing-away lattice 4.3 Description of rigging work

(A) - For on-road driving – A pin (1) is in the holder (2) and is secured with the retaining pin.

– A pin (1) is in the slewing connection (3) and is secured with the retaining pin.

(B) – For crane operation with main boom – The slewing connection (3) has been p. 4 - 58. undone;

à

– Two pins (1) are in the holder (2) and are secured with retaining pins.

If only section 2 is folded against the main boom:

– The connection at the rear is established (lever (1) in position A); p. 4 - 43.

à

– Pins not needed (2) from the connection part 1/part 2 (2) have been stored in the holder.

à p. 4 - 50.

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– The middle connection (3) is in position section 2/main boom;

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Swing-away lattice 4.3 Description of rigging work

4.3.3

To move the swivel ram into the rigging/telescoping position If you activate the swivel ram, the rear and front connections must be made.

In the rigging position the swivel ram must be retracted so that the slewing connection (1) is aligned.

In the telescope position the swivel ram is fully extended. The forks and other parts of the slewing connection (1) are then clear and free to move.

Prerequisites – The hand-held control unit is connected to derrick the swing-away lattice.

– The electrical connection to the main boom has now been made.

– The engine for crane operation is running.

Pre-select derrick swing-away lattice

• Press the button (1).

– Indicator lamp in key will light up.

Extending/retracting the swivel ram

• Press the button combination for the desired movement: 1 Extend swivel ram 2 Retract swivel ram The further in you press the button (1) or (2), 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.

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Swing-away lattice 4.3 Description of rigging work

4.3.4

Making/releasing the front connection At the front connection the swing-away lattice is joined to the swivel ram.

This connection needs to be made if the swing-away lattice is slewed against the main boom during unrigging or installation.

The connection must be removed if the swing-away lattice is being rigged or removed.

To make the connection

G

There is a risk of accidents due to the swing-away lattice falling.

Always fix section 1 with the pins inserted and locked in connecting point (1). If section 1 is only resting on the holder, the swing-away lattice can fall down and injure you or somebody else.

The swing-away lattice is swivelled against the main boom so that the parts of connection point (1) are aligned. The swivel ram is in the telescope position.

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

• Secure the pin with a retaining pin.

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Swing-away lattice 4.3 Description of rigging work

Undoing the connection

G G

There is a risk of accidents due to the swing-away lattice falling.

Before removing the connection, make sure that the slewing connection is made.

This will prevent the swing-away lattice from falling when the connection is removed and causing injury to you or other persons.

There is a risk of accidents due to the swing-away lattice swinging of its own accord.

Always secure the swing-away lattice with a guide rope on the main boom before undoing the connection.

This will prevent the swing-away lattice from swinging around of its own accord and pushing you off the crane base or causing injury to you or other persons.

The slewing connection has been made;

à p. 4 - 57.

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

• Insert the pin into the holder (2) and secure

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it with a retaining pin.

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Swing-away lattice 4.3 Description of rigging work

4.3.5

Making/releasing the rear connection When the rear connection is undone, the front connection and the slewing connection must have been made.

Establishing the connection The lever (1) must be in position A – the locking bar (2) can engage.

• Pull the lever: – down as far as it will go, – then a bit outward and let it slide against the spring force into position A.

• Derrick the swing-away lattice to position 3;

à p. 4 - 44.

• Swing the swing-away lattice to its full extent towards the main boom.

• Derrick the swing-away lattice to position 2.

The swing-away lattice will be lowered into a holder. The locking bar (1) will engage via spring force.

Undoing the connection The lever (1) must be in position B – the locking bar is retracted.

• Pull the lever (1) down out of position A until it engages in position B. Locking bar (1) is now retracted.

• Derrick the swing-away lattice to position 3;

à p. 4 - 44.

• Use the swivel ram to swivel the swingaway lattice outwards.

• Derrick the swing-away lattice to position 2.

After the swing-away lattice has been swivelled outward:

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• put the lever in position A.

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Swing-away lattice 4.3 Description of rigging work

4.3.6

Derricking cylinder positions There are 3 markings on the derricking cylinder which ease operation when swivelling.

Each position has been reached when the pointer (A) is on the marking (B).

1 The swing-away lattice has been lowered to take the stress off of the front connection.

2 The swing-away lattice has been lowered so far to be able to swivel in the fork elements of the installed section 2.

3 The swing-away lattice has been lowered far enough to be able to be swivelled out from the rear connection.

To derrick the swing-away lattice jib with the hand-held control unit; p. 4 - 82.

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à

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Swing-away lattice 4.3 Description of rigging work

4.3.7

Position of the hydraulic connections Before operating the lattice extension, you must ensure the hydraulic connections are in the lattice extension operation position.

Before working with the main boom for longer periods of time, you must place the hydraulic connections in the Main boom operation position, so that the hoses are not put under unnecessary strain.

G G Working with the lattice extension

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.

There is a risk of an accident when pulling sideways.

When you are standing on the ladder, you will have to pull the hoses. You may fall from the ladder doing this. Make sure that the ladder is positioned securely.

The locking device on the hose drum must be released;

à p. 4 - 47.

Attaching the hoses

• Remove the linchpins (3) and fold up the guide sheaves (4).

• Remove the hoses (5) from the clamp (1) and fasten them to the clamp (2).

• Fold down the guide sheaves (4) and secure them with the linchpins (3).

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Swing-away lattice 4.3 Description of rigging work

Main boom operation

The locking device on the hose drum must be released;

à p. 4 - 47.

Attaching the hoses

• Remove the linchpins (3) and fold up the guide sheaves (4).

• Remove the hoses from the clamp (2) and fasten them to the clamp (1).

• Fold down the guide sheaves (4) and secure them with the linchpins (3).

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Swing-away lattice 4.3 Description of rigging work

4.3.8

Checking the locking device on the hose drum The locking device must be undone before you operate with a lattice extension.

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

S G

Risk of damage to the hoses Always check if the locking device is released before beginning operation with a lattice extension.

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 inserted before the hose drum is removed. Otherwise, the hose drum will rotate uncontrollably against the holder and could injure you.

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

A – Releasing the rotation lock

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

B – Inserting the rotation lock

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

• Rotate the spring latch (2) so that it

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

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4 - 47

Swing-away lattice 4.3 Description of rigging work

4.3.9

Making/breaking the hydraulic connection Making the hydraulic connection

• If necessary, bring the connections (1) into the position for lattice extension operation; p. 4 - 45.

à

• Remove the hose line (2) from the clamp (4).

• Feed the hose lines towards the left hand side though the lower opening (3) in section 1 under the boom head.

• Remove the protective caps to the connections (1) and attach the hose lines (observe the colour code).

S

There is a risk of damage to the hydraulic hoses!

Feed the hydraulic hoses under the main boom head in such a way that they hang freely. Take care that the hoses are not ripped off when folding the lattice extension. This prevents damage to the hydraulic hoses.

Disconnecting the hydraulic connection

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

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

• Secure the hoses on the holder (3) on

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section 1.

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Swing-away lattice 4.3 Description of rigging work

4.3.10

Centre connection For the middle connection, there are three positions.

– Section 1/section 2 position – Section 2/main boom position – At section 1 position

Section 1/ section 2 position

This position must be established in the following circumstances: – when rigging the 21 m swing-away lattice – before the swing-away lattice is swung in front of the main boom head, – when derigging the 21 m swing-away lattice – after section 2 has been swung towards section 1, – when derigging the 12 m swing-away lattice – if section 2 is fitted to the main boom, – before removing the 21 m swing-away lattice.

• Fasten the locking bar (1) to section 1 with the pin (2).

• Fasten the locking bar (1) to section 2 with the pin (3).

• Secure the pins using the retaining pins.

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Swing-away lattice 4.3 Description of rigging work

Section 2/main boom position

This position must be established in the following circumstances: – when rigging the 12 m swing-away lattice – if section 2 is fitted.

– before removing – when only section 1 is to be removed.

This position must be released if only section 2 is to be installed or removed.

Establishing the position

• Fasten the locking bar (1) to the main boom with the pin (2).

• Fasten the locking bar (1) to section 2 with the pin (3).

• Secure the pins using the retaining pins.

Undoing the position

• Attach a sling to section 2; à p. 3 - 5.

• (A) – Pull out the pin (2).

• (B) – Fold down the locking bar (1).

• Insert the pin (2) into the locking bar (1).

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

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Swing-away lattice 4.3 Description of rigging work

Position at section 1

This position must be established in the following circumstances: – When rigging the 21 m swing-away lattice – before section 2 is swung in front of section 1.

• Fasten the locking bar (1) to section 1 with the pins (2) and (3).

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• Secure the pins using the retaining pins.

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Swing-away lattice 4.3 Description of rigging work

4.3.11

Making/breaking section 1/section 2 connections This connection is made after the 12 m swing-away lattice has been swung to the side of the main boom during derigging.

This connection is removed before the 12 m swing-away lattice is swung in front of the main boom during rigging.

To make the connection

G

There is a risk of crushing.

While swivelling, keep your hands away from section 1 and section 2.

This will prevent your fingers and hands from being crushed.

• (A) – Swivel section 2 against section 1.

• Remove the conical pin (5) from the bearing point (4).

• Swivel section 2 to section 1 until the bearing points are aligned.

• (B) – Insert the conical pin (4) into the lower connecting point (5) and secure it with a retaining pin.

• Pull the pin (2) out of the holder (1).

• Put the pin (2) into the upper connecting

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point (3) and secure it with a retaining pin.

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Swing-away lattice 4.3 Description of rigging work

Undoing the connection

• Before releasing the connection, check that

à p. 4 - 41.

– The slewing connection has been made; à p. 4 - 57.

– The front connection has been made;

– The middle connection is in the section 2/main boom position; – The rear connection has been made;

G

à p. 4 - 50.

à p. 4 - 41.

There is a risk of accidents due to falling parts!

Before undoing the connection, make sure all of the aforementioned connections have been made.

In this way you will prevent either section 2 or section 1 or both falling down when the connection is released.

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

• Plug the pin (2) into the holder (1) and secure it with a retaining pin.

• Remove the conical pin (4) from the connecting point (5).

• (B) – Swing section 1 approx. 15 cm outwards.

• Put the pin (4) into the connecting point (5)

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and secure it with a retaining pin.

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Swing-away lattice 4.3 Description of rigging work

4.3.12

Connections on the left and right of the main boom head

The connections must be made after the swing-away lattice has been swung in front of the main boom head during rigging.

The connections must be released so that the swing-away lattice can be swung to the side of the main boom during unrigging.

G

Risk of accidents from lattice extension swinging of its own accord Always secure the swing-away lattice with a guide rope before removing any connections.

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

Making connections

G

There is a risk of accidents from a falling lattice extension.

Before swinging the swing-away lattice in front of the main boom head the connection, make sure that the slewing connection is made. This will prevent the swing-away lattice from falling as it is turned and causing injury to you or other persons.

Left-hand connection

• Swing the lattice extension in front of the main boom until the connecting points (2) align.

• Remove the pins from the holder (1).

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

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• Secure the bolts using retaining pins.

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Swing-away lattice 4.3 Description of rigging work

Right hand connections

• Remove the pins from the holder (1).

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

• Secure the bolts using retaining pins.

Releasing connections

G G

Right-hand connection Only release this connection when the connection on the left-hand side is still intact.

Danger of crushing if procedure is not followed Release the right-hand connection first, and then the left-hand connection.

In this way you prevent the swing-away lattice from swinging round when you release the right-hand connection, which could knock you from the ladder or lead to you becoming crushed between the swing-away lattice and the main boom.

There is a risk of accidents from a falling lattice extension.

On this side, only release the two inner pins. The outerpins for the slewing connection must remain inserted.

If you release the slewing connection, the lattice extension will fall down when the pins on the left-hand side are released and could injure yourself or other people.

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Swing-away lattice 4.3 Description of rigging work

The pins (3) for the slewing connection must remain inserted.

• Pull the pin out of the connecting point (2).

• Insert the pins into the holder (1).

• Secure the pins using the retaining pins.

Left-hand connection

H

Only release the left-hand connection after the right-hand connection has been released. The left-hand connection stops the lattice extension from swinging round when the right-hand connection is released.

• Pull the pin out of the connecting point (2).

• Insert the pins into the holder (1).

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• Secure the pins using the retaining pins.

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Swing-away lattice 4.3 Description of rigging work

4.3.13

Making/breaking the slewing connection The slewing connection must be made before the swing-away lattice has been swivelled in front of the main boom head during rigging.

The connection must be released after the swing-away lattice is swivelled onto the main boom side and pinned there during derigging.

To make the connection

The connecting points for the slewing connection will only align if the main boom is completely telescoped in and the swivel ram is in the rigging position.

If necessary: a slewing connection has been established during on-road driving for safety reasons.

• Pull the pins (2) out of the holder (1).

• Insert the pins (2) into the connecting points (3).

• Secure the pins using the retaining pins.

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Swing-away lattice 4.3 Description of rigging work

Undoing the connection

G

There is a risk of accidents due to the swing-away lattice falling.

Make sure that when the swing-away lattice is folded to the side, that the following connections are made.

à

– Make the front connection; p. 4 - 41.

– For a rigged 21 m swing-away lattice, the rear connection; p. 4 - 43, – For a rigged 12 m swing-away lattice, the section 1/section 2 connection; p. 4 - 52.

à

à

In this way you prevent the lattice extension from slipping or falling from the boom when it is operated again after the connection is released and causing injury to you or other persons.

G G

Risk of crushing due to swinging swing-away lattice When removing, always secure the swing-away lattice with a guide rope before releasing the slewing connection, and only insert the pins in the holders when the swing-away lattice has been set down.

In this way you prevent the swinging swing-away lattice from knocking you off the ladder, or crushing you against the main boom.

Risk of accidents if the permissible vehicle is exceeded.

When the swing-away lattice is folded onto the main boom for transport, it must be secured in the slewing connection with a pin.

Otherwise the swing-away lattice can swing out by itself if the hydraulics of the swivel ram is damaged.

If this happens, the permissible vehicle will be exceeded.

(A) - For on-road driving

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

• Insert the pin (2) into the holder (1) and secure it with a retaining pin.

The pin (4) remains inserted and secured in the connecting point (5).

(B) – For crane operation with main boom

• Pull the pins (2) and (4) out of the connecting • Insert the pins in the holder (1) and secure them with one retaining pin each.

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points (3) and (5).

Swing-away lattice 4.3 Description of rigging work

4.3.14

To move the swivel ram into the rigging/telescoping position This section describes how to swivel the swing-away lattice towards or away from the main boom.

The swivel ram is built into the front connection, which can be extended and retracted using the manual control unit.

Prerequisites

(A)

The swivel ram is retracted

Rigging position

(B)

The swivel ram is extended

Telescope position

à p. 4 - 41.

– The rear connection has been made; à p. 4 - 43.

– The front connection has been made;

– The hand-held control unit is connected to derrick the swing-away lattice; p. 4 - 82.

à

– The engine for crane operation is running.

G Rigging position

There is a risk of accidents due to the swing-away lattice falling.

Make sure that the front and rear connections have been made before swinging the swing-away lattice.

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

Make sure that all the above conditions are met.

• Press the button (1). The lamp in the button will illuminate.

• Press the button (2).

• Press the button (3) at the same time.

The further you press button (3), the quicker the movement will be.

Press button (3) until the swivel ram is retracted so far that the slewing connection (4) is aligned.

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Swing-away lattice 4.3 Description of rigging work

Telescope position

Make sure that all the above conditions are met.

• Press the button (1). The lamp in the button will illuminate.

• Press the button (2).

• Press the button (3) at the same time.

The further you press button (3), the quicker the movement will be.

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Press the button (3) until the swivel ram is fully extended. The forks and other parts of the slewing connection (1) are then clear and free to move.

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Swing-away lattice 4.3 Description of rigging work

4.3.15

Swinging the swing-away lattice when rigging

When rigging – section 1

When rigging the 12 m or 21 m swing-away lattice, you must swing section 1 in front of the main boom head.

• Check whether the following prerequisites are met.

à

– The slewing connection has been made; p. 4 - 57.

– The swing-away lattice is secured with a guide rope; p. 4 - 35. p. 4 - 41.

– The front connection has been made; – The swivel ram is in the telescope position; p. 4 - 60.

à

G

à

à

Risk of accidents due to the swing-away lattice swinging of its own accord Always secure the swing-away lattice with a guide rope before swinging it.

Make sure that there are no people or objects in the slewing range of the swing-away lattice and always swing out the swing-away lattice with a guide rope from the ground.

When the front connection is undone, the swinging process will begin.

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

If you are alone and have attached the guide rope to the crane when securing, the swing-away lattice will now swing only until the guide rope is taut.

You can now swing the swing-away lattice in front of the main boom head using with the guide rope.

H

You may need to trigger the swinging procedure by pulling on the guide rope.

If section 1 will not swing to section 2, then derrick the swing-away lattice Derricking up or down a little until the connecting point is free to move; the swing-away lattice, p. 4 - 82.

à

• From the ground, use the guide rope to pull the swing-away lattice in front of the main boom head.

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Swing-away lattice 4.3 Description of rigging work

When unrigging – section 1

When unrigging the 12 m or 21 m swing-away lattice extension, you must swing section 1 to the side of the main boom.

• Check whether the following prerequisites are met.

à

– The slewing connection has been made; p. 4 - 57.

– The swing-away lattice is secured with a guide rope; p. 4 - 35.

– The swivel ram is in the telescope position; p. 4 - 60.

à

G

à

Risk of accidents due to the swing-away lattice swinging of its own accord Always secure the swing-away lattice with a guide rope before swinging it.

Make sure that there are no people or objects in the slewing range of the swing-away lattice and always swing out the swing-away lattice with a guide rope from the ground.

• Fasten a guide rope at the front of section 1 and lay the guide rope over the clamp (1) at the rear of the main boom.

• Derrick the swing-away lattice to position 2; à p. 4 - 44.

• Swing the swing-away lattice as far as the front connection.

• Make the front connection; à p. 4 - 41.

When rigging – section 2

G

When rigging the 21 m swing-away lattice you must also swing out section 2 in front of section 1.

Risk of accidents through section 2 swinging of its own accord Always secure section 2 with a guide rope before you release the connection between section 1 and section 2 and only position the ladder on the left at section 1.

In this way you prevent section 2 from swinging round of its own accord when the connection is released and knocking you off the ladder.

• Fasten a guide rope to the front at section 2.

• Secure section 2 against swinging round.

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Get a helper to hold the guide rope taut, or fasten it to the bottom of section 1.

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Swing-away lattice 4.3 Description of rigging work

• Bring middle connection into the position on section 1; à p. 4 - 65.

G

Risk of accidents through section 2 swinging round Make sure that there are no people or objects in the slewing range of the swing-away lattice and always swing out the swing-away lattice with a guide rope from the ground.

• Swing section 2 in front of section 1 using the guide rope.

• Secure section 2 against swinging round.

Get a helper to hold the guide rope taut.

• If you are working alone, secure section 2 on the left-hand side at section 1 using a second guide rope (1) to prevent it from swinging round.

• Make the left-hand connection between section 2 and section 1;

à p. 4 - 65.

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Swing-away lattice 4.3 Description of rigging work

When unrigging – section 2

When unrigging the 21 m swing-away lattice, you must swing section 2 to the side of section 1.

H

Check that the electrical connection between section 1 and section 2 is broken before you swing section 2 towards section 1. It is difficult to reach the electrical connection after section 2 has been swung round.

• Secure section 2 against swinging round.

Get a helper to hold the guide rope taut.

• If you are working alone, secure section 2 from swinging round on the left-hand side at section 1 using a second guide rope (1).

• Release the left-hand connection between section 2 and section 1;

à p. 4 - 65.

G

Risk of accidents through section 2 swinging round Make sure that there are no people or objects in the slewing range of the swing-away lattice and always swing out the swing-away lattice with a guide rope from the ground.

• Swing section 2 to the side of section 1 using the guide rope.

G

Risk of accidents through section 2 swinging of its own accord Always secure section 2 with a guide rope before you make the connection between section 1 and section 2 and only position the ladder on the left at section 1.

In this way you prevent section 2 from swinging round of its own accord and knocking you off the ladder.

• Secure section 2 against swinging round.

Get a helper to hold the guide rope taut, or fasten it to the bottom of section 1.

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• Move the middle connection to the section 1/section 2 position; à p. 4 - 49.

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Swing-away lattice 4.3 Description of rigging work

4.3.16

Making/breaking connections to the swing-away lattice (A) – If section 1 and section 2 are folded up on the side for transportation, you only need to make and break the connection on the left-hand side.

(B) – If the swing-away lattice is transported on a separate vehicle and if section 2 is to be removed for that.

Section 1 and section 2 fitted

G

The connection is made after section 2 is swung in front of section 1.

The connection is undone before section 2 is folded on to the side of section 1.

Risk of accidents through section 2 swinging of its own accord Always secure section 2 with a guide rope and only position the ladder on the left of section 1. In this way you prevent section 2 from swinging round of its own accord and knocking you off the ladder.

To make the connection

• Take the pins (2) out of the holder (1).

• Insert the pins (2) into the connecting points (3).

• Secure the bolts using retaining pins.

• Take the pin (5) out of the holder (1).

• Insert the pin (5) into the connecting point (4).

• Secure the pin with the retaining pin.

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G

There is a risk of accidents from a falling lattice extension.

Ensure that when the connection between section 1 and section 2 has been made, that three pins have been inserted on the right-hand side.

The thin pin is not designed to withstand the load during operation. The lattice extension will fall down if the thin pin breaks. This may lead to injury and even death to yourself or other people.

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Swing-away lattice 4.3 Description of rigging work

Undoing the connection

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

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

• Remove the pins (5) from the connecting points (4).

• Plug the pins (5) into the holder (1).

• Secure the pins using the retaining pins.

Only section 1 is fitted

G

Danger of crushing by swinging section 2 Always secure section 2 with a guide rope from the ground before making or breaking the connection.

In this way you prevent the swinging lattice extension from knocking you off the ladder, or you being crushed between the sections of the swingaway lattice.

• Attach a guide rope to section 2.

• Sling section 2 on to an auxiliary crane; à p. 3 - 5.

To make the connection

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

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Swing-away lattice 4.3 Description of rigging work

• Position section 2 so that the connecting points (3) and (5) align.

• Insert the thin pin (4) into the connecting point (5) on the lower right.

• Secure the pin (4) with a retaining pin.

• Remove the retaining pins and remove the pins (2) from the retaining sheet (1).

• Insert the pins (2) into the connecting points (3) on both sides.

• Secure all pins (2) with retaining pins.

Undoing the connection

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

• Insert the pins (1) into the retaining sheet (3) and secure them with retaining pins.

• Take the pin out of the connecting point (4).

• Lift section 2 off from section 1.

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• Insert the thin pins into the connecting point in section 2.

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Swing-away lattice 4.3 Description of rigging work

4.3.17

G

Electrical connections to the swing-away lattice 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 around.

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

12 m swing-away lattice Making an electrical connection

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

• Unwind the cable (5) from the holder (7).

• Change over the plug (4) from the dummy socket (6) and to the socket (3).

• Wind up the cable (5) far enough on the holder (7) so that it does not sag.

• Check whether the bridging plug (2) is

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inserted in the socket (1) at the front on section 1.

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Swing-away lattice 4.3 Description of rigging work

Disconnecting the electrical connection

• Remove the plug (4) from the socket (3) and plug it into the dummy socket (6).

• Wind the cable (5) on to the holder (7).

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

21 m swing-away lattice

• First make the electrical connection for the 12 m swing-away lattice extension;

à p. 4 - 68.

Making an electrical connection

• Remove the bridging plug (5) from the socket (1) and plug it into the dummy socket (4).

• Unwind the cable (3) from the holder (6).

• Change over the plug (2) from the dummy socket (4) to the socket (1).

• Wind up the cable (3) far enough on the holder (6) so that it does not sag.

S

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

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Swing-away lattice 4.3 Description of rigging work

Disconnecting the electrical connection

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

• Wind the cable (3) on to the holder (6).

• Remove the bridging plug (5) from the socket (4) and plug it into the socket (1).

• Undo the electrical connection on the 12 m

à p. 4 - 68.

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swing-away lattice;

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Swing-away lattice 4.3 Description of rigging work

4.3.18

Folding deflection sheaves out/in

Folding out the deflection sheaves

G

Risk of crushing!

Always hold the deflection sheave firmly by the handle when removing the pins.

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

Rear deflection sheave

• (A) – Unscrew the retaining pin from the pin (2).

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

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

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

Front deflection sheave

• (A) – Unscrew the retaining pin from the pin (3).

• Hold the deflection sheave by the handle (1) and pull out the pin (3).

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

• Secure the pin (3) using the retaining pin.

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4 - 71

Swing-away lattice 4.3 Description of rigging work

Folding in the deflection sheaves

G G

For driving with the folded in swing-away lattice, you must fold in the deflection sheaves.

Risk of accidents from exceeding the permissible overall height!

Always fold in the deflection sheaves when the swing-away lattice is folded on the main boom for driving. When the deflection sheaves are folded out, the overall height specified for on-road driving is exceeded.

There is a risk of crushing.

When you pull out the pins, always keep a firm grip on the Rear deflection sleeve with the handle, and keep at firm grip on the Front deflection sheave at the strut.

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

Rear deflection sheave

• (A) – Unscrew the retaining pin from the pin (2).

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

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

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

Front deflection sheave

• (A) – Unscrew the retaining pin from the pin (3).

• Hold the deflection sheave by the handle (1) and pull out the pin (3).

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

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• Secure the pin (3) using the retaining pin.

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Swing-away lattice 4.3 Description of rigging work

4.3.19

G Possible reeving methods

Positioning/removing the hoist rope There is a 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, falling down and injuring people.

Reeving the hoist rope into the hook block; à GMK 6300L-1 operating manual.

1 sheave hook blocke Maximum load bearing capacity of the hook block: 32 t Max. load bearing capacity with the GMK 6300L-1 Reeving

Maximum lifting capacity

A 2 fall

21,0 t

B

10,5 t

1 fall

• With a 2 x reeving, fasten the rope end clamp to the attachment plate (1).

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Swing-away lattice 4.3 Description of rigging work

Hook tackle Maximum load bearing capacity of the hook tackle: 12 t Max. load bearing capacity with the GMK 6300L-1

Fitting/removing the hoist rope

Reeving

Maximum lifting capacity

A

10.5 t

1 fall

On the 12 m swing-away lattice (A) On the 21 m swing-away lattice (B)

Fitting the hoist rope

• Remove the sheaves (1).

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

reeved once or twice, depending on the length of swing-away lattice; p. 4 - 76.

à

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• Put all sheaves (1) back in place and secure them with retaining pins.

• Attach the hook tackle or the hook block. The hoist rope may now be

Swing-away lattice 4.3 Description of rigging work

Removing the hoist rope

• Unreeve the hook block.

• Remove the sheaves (1).

• Take the hoist rope off the head sheave (2) and the deflection sheaves (4), (3) and place it on the ground on the left side.

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• Put all sheaves back in place and secure them with retaining pins.

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4 - 75

Swing-away lattice 4.3 Description of rigging work

4.3.20

Installing/removing the lifting limit switch The functions lift hoist, extend main boom telescoping, lower the main boom and derrick swing-away latticeare monitored by the lifting limit switch on the swing-away lattice and are switched off, if necessary.

Connection to the main boom If the lifting limit switch is removed from the main boom, both connections must be bridged (1); GMK 6300L-1 operating manual.

à

If a lifting limit switch remains attached to the main boom, the lifting limit switch must be disabled; GMK 6300L-1 operating manual.

à

On the 12 m swing-away lattice Connecting the lifting limit switch

• Fit the lifting limit switch (2) on to the holder (1) and secure it with a retaining pin.

• Remove the bridging plug (5) from the socket (3) and plug it into the dummy socket (4).

• Lay the connecting cable (6) in such a way

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that it will not be damaged during crane operation, and connect the lifting limit switch to the socket (3).

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Swing-away lattice 4.3 Description of rigging work

Removing the lifting limit switch

• Pull the plug from the socket (3).

• Remove the bridging plug (5) from the dummy socket (4) and plug it into the socket (3).

• Remove the lifting limit switch (2) from the holder (1).

• Fasten the retaining pin to the lifting limit switch.

On the 21 m swing-away lattice Connecting the lifting limit switch

• Fit the lifting limit switch (2) on to the holder (1) and secure it with a retaining pin.

• Lay the connecting cable (4) in such a way that it will not be damaged during crane operation, and connect the lifting limit switch to the socket (1).

For operation with the 21 m swing-away lattice, the connection for the lifting limit switch must be bridged on the 12 m swing-away lattice with the short-circuit plug (5).

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Swing-away lattice 4.3 Description of rigging work

Removing the lifting limit switch

• Pull the plug from the socket (3).

• Remove the lifting limit switch (2) from the holder (1).

• Fasten the retaining pin to the lifting limit

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Swing-away lattice 4.3 Description of rigging work

4.3.21

Anemometer and air traffic control light

Installing

The anemometer and the air traffic control light (both additional equipment) are on the same rod.

On the 21 m swing-away lattice

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

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

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

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

On the 12 m swing-away lattice

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

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

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

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

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Swing-away lattice 4.3 Description of rigging work

Switching the air traffic control light on and off :

Removing

S

Switching on:

Press in switch (1) at the bottom

Switching off:

Press in switch (1) at the top

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

Risk of damage during on-road driving!

Always remove the anemometer and air traffic control light before on-road driving.

This prevents the specified overall height from being exceeded at on-road level, and the anemometer from getting damaged due to air currents.

• Switch off the air traffic control light – press the switch (1) upwards and inwards.

On the 21 m swing-away lattice

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

• Wind the cables onto the holders (4).

• Take the rod (3) out of clamp (5).

• For transportation, fasten the retaining pins

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to the rod (3).

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Swing-away lattice 4.3 Description of rigging work

On the 12 m swing-away lattice

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

• Wind the cables onto the holders (4).

• Take the rod (3) out of clamp (5).

• For transportation, fasten the retaining

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pins to the rod (3).

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4 - 81

Swing-away lattice 4.3 Description of rigging work

4.3.22

Derricking the swing-away lattice In this section you will find details about derricking the swing-away lattice when rigging. Derricking the swing-away lattice in operation; p. 4 - 89.

à

In order to enable the derricking of the swing-away lattice the SLI code must be set for the current rigging mode; Setting the SLI, p. 4 - 85.

à

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

– Raising: Press the buttons (1) and (3) – the swing-away lattice is raised.

– Lowering: Press the buttons (2) and (3) – the swing-away lattice is lowered.

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 since you cannot see the folded swingaway lattice from this point.

This socket (2) is intended for emergency operation.

• Connect the hand-held control to the socket

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(1).

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Swing-away lattice 4.3 Description of rigging work

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

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

Pre-select derrick swing-away lattice

• Press the button (1).

– Indicator lamp in key will light up.

Lifting/lowering swing-away lattice

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

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Swing-away lattice 4.3 Description of rigging work

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Swing-away lattice 4.4 Operation with swing-away lattice

4.4

Operation with swing-away lattice

H

When operating the swing-away lattice, the maximum speed for the different power units is limited to 70%, GMK 6300L-1 operating manual.

à

The raising, lowering, slewing, derricking and telescoping movements 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 installed swing-away lattice.

4.4.1

Setting the SLI

H Entering the SLI code

If a hook block is reeved on the main boom during operation with the lattice extension, the loads given in the lifting capacity tables decrease and the SLI subsequently switches off earlier.

The values which must be deducted from the load capacities depend on the length of the lattice extension and the weight of the hook block. You will find a table with the values in the lifting capacity tables in the section Information on working with the swing-away lattice extension.

• Enter the current rigging mode on the SLI, either using the corresponding SLI code according to the lifting capacity table or using the individual components.

When operating with the swing-away lattice you must also enter the length of the swing-away lattice.

• Enter the current reeving at the SLI. • Check whether the current rigging mode of the truck crane corresponds to the displayed rigging mode.

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4 - 85

Swing-away lattice 4.4 Operation with swing-away lattice

• Check: 1 The current swing-away lattice angle 2 The length of the rigged swing-away lattice 3 The number of reeved rope lines 4 The hoist that is switched on 5 The rigged counterweight 6 The rigged outrigger span

Load bearing capacities When the telescopic sections are telescoped to a fixed length during GMK 6300L-1, the SLI releases the lifting capacity now according to the lifting capacity table and the display Maximum load (1) shows the associated value.

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Depending on the current angle, the SLI automatically switches to the capacity diagrams for fixed angles (5° inclination) and intermediate angles (5-20° or 20-40° inclination) when this is permitted for the load currently being raised.

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Swing-away lattice 4.4 Operation with swing-away lattice

4.4.2

G

Derricking the main boom Risk of accidents if the SLI is overridden!

Do not override the SLI when lowering the boom into a horizontal position.

If the SLI is overridden, the crane operations will not be monitored and the truck crane will overturn if you leave the permissible working range.

If the following requirements are met, lowering into the horizontal position with swing-away lattice and a slewing range of 360° is permitted and is monitored by the SLI. – The current rigging mode with the rigged swing-away lattice is entered on the SLI, and the corresponding SLI code is displayed as per the Lifting capacity table.

– The current reeving type on the swing-away lattice is entered for the hoisting gear whose hoist rope is reeved on the swing-away lattice.

– Apart from the hook block, there is no load on the swing-away lattice.

– The main boom is fully retracted.

The SLI will only release the main boom for raising and setting it down when the main boom is completely retracted.

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When all of the above requirements have been satisfied, the SLI will automatically switch to the rigging tables and derricking can then be done in the angle range underneath the working range of approx. 15°.

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4 - 87

Swing-away lattice 4.4 Operation with swing-away lattice

4.4.3

telescoping with rigged heavy load lattice extension

Slewing range of 360°

S

Risk of overloading of the main boom If you are telescoping the main boom with the rigged swing-away lattice, you may not simultaneously slew the superstructure.

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

The telescoping of the main boom with a rigged swing-away lattice is monitored by the SLI. Telescoping will only be enabled if the main boom is derricked to a certain angle and a maximum permissible load is not exceeded.

The required angle (between 75° and 78°) depends on the rigging mode of the truck crane.

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

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

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

à GMK 6300L-1 operating manual.

Span of 6.30 x 8.70 m

S

Risk of overturning backwards!

Given a span of 6.30 x 8.70 m and a lateral main boom position, telescoping is prohibited. There is a risk of overturning backwards.

Do not override the SLI. If the swing-away lattice is rigged into position on the side,

If the main boom angle is too large for telescoping with the swing-away lattice, the SLI displays an appropriate error message.

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– raise the main boom, – slew the superstructure backwards into the 0° position and switch off the slewing gear, – telescope the main boom to the required length, – switch on the slewing gear and slew the superstructure to the side.

Swing-away lattice 4.4 Operation with swing-away lattice

4.4.4

Derricking the swing-away lattice

Switching on the derricking gear

All power units are switched off and the lamps in the corresponding buttons light up only dimly after the ignition is switched on.

• Press the button (1) once.

– The lamp in button (1) lights up brightly.

– The symbol (2) is green if 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 operation are switched off.

Raising and lowering

G

You can adjust the sensitivity of the control levers to the operating conditions; GMK 6300L-1 operating manual.

à

Risk of accidents due to unexpected crane movements!

In the case of multiple configuration, check whether the control lever function Derricking is switched on before you move the control lever for derricking.

This way, you avoid accidents due to unexpected crane movements.

To lower:

Push the control lever to the right – the swing-away lattice will be lowered.

To raise:

Push the control lever to the left – the swing-away lattice will be raised.

The maximum derricking speed is automatically reduced as the system length is increased. If you now reduce the working radius (e.g. by retracting the telescoping), the derricking speed is automatically increased again.

You can set the desired engine speed (idling speed) with the button (1);

à GMK 6300L-1 operating manual.

You can limit the maximum derricking speed; à GMK 6300L-1 operating manual.

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4 - 89

Swing-away lattice 4.4 Operation with swing-away lattice

When the swing-away lattice is derricked, the SLI automatically switches to the values specified in the lifting capacity table for fixed angles (5° inclination) and intermediate angles (5-20° or 20-40° inclination) when this is permitted for the load currently being raised.

If this switchover is not permitted for the load currently raised, derricking will be switched off and a corresponding error message will be generated.

The swing-away lattice can be derricked under load. The derricking last is limited; Lifting capacity table. If the limit is exceeded, lowering is deactivated.

à

Switching off the derricking gear

• Press the button (1) once.

– The lamp in the button (1) lights up dimly.

– The symbol (2) is red if the derricking gear is switched off.

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All power units are switched off and the lamps in the corresponding buttons light up only dimly after turning off the ignition.

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Swing-away lattice 4.4 Operation with swing-away lattice

4.4.5

Information about the SLI shutdown Operation with the swing-away lattice is monitored by the SLI. When operating with the swing-away lattice, SLI shutdowns may occur for GMK 6300Lthe same reasons as when operating with the main boom; 1 operating manual.

à

Additional reasons for a shutdown

When operating with a derricking swing-away lattice: – Different lifting capacities are released for the angles 5°, 0-20° and 20 - 40°. Lowering the swing-away lattice can lead to the SLI shutting down when the currently raised load is not permitted in the newly reached angle range.

– For the above-named angles, the swing-away lattice can be derricked under load. If the current load is greater than permitted for the angle range, the lowering of the swing-away lattice is stopped by the SLI. – When the SLI has shut down, the Lower swing-away lattice movement and all other movements which increase the load moment are blocked.

4.4.6

G

Procedure if permissible wind speed is exceeded Risk of accidents due to excessively high wind speeds!

If the current wind speed is higher that the maximum permissible wind speed, stop crane operation immediately and restore the corresponding rigging mode.

This prevents the truck crane from overturning due to overloading.

• Prior to and during crane operation, check whether the actual 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 GMK 6300L-1 operating manual.

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

• Immediately stop crane operations.

• Bring the truck crane into the rigging mode specified for the current wind 12.03.2018

speed in the Lifting capacity table.

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4 - 91

Swing-away lattice 4.4 Operation with swing-away lattice

4.4.7

Information about the main boom operation when the swingaway lattice is folded/rigged

Folded

This section applies to instances when the swing-away lattice is folded at the side.

If a swing-away lattice is folded at the side during operation with the main boom, the loads given in the Lifting capacity tables decrease.

The relevant formulas and examples for calculating these values during operations planning can be found in the Lifting capacity table.

The decreased values are shown directly on the SLI insert in the Maximum load display (1).

Rigged

S

This section applies when the swing-away lattice is rigged and locked to the main boom head.

Risk of overturning with impermissible rigging mode Main boom operation with a rigged swing-away lattice is only permissible in rigging modes that are also permissible for the rigged swing-away lattice (outrigger span, counterweight, slewing range).

If you set up rigging modes that are only valid for main boom operation without a rigged swing-away lattice (e.g. Free on wheels working position), then the truck crane could overturn during operation.

For operation with the main boom with a rigged swing-away lattice, you must enter the current rigging mode for the main boom without a swingaway lattice on the SLI.

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The values given in the corresponding Lifting capacity table for the lifting capacities and for the permissible wind speeds decrease in this case.

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Swing-away lattice 4.4 Operation with swing-away lattice

Reduction of the lifting capacity The maximum load display (1) does not show the reduced values.

The SLI also takes into account the load moment affected by the currently rigged swing-away lattice and will correspondingly switch off earlier.

In the Lifting capacity table, you will find table with values for reducing the lifting capacities. The given values for reduction are only maximum values for certain rigging modes (angle and length of main boom and lattice extension).

The SLI, however, takes into account the value for the currently rigged swing-away lattice, adds the weight of the raised load and displays the sum on the Current load display (1).

The displayed value could deviate from the value that was previously calculated during the operations planning.

If this is the case, the SLI is not defective. Do not override the SLI, even if the displayed value is higher than the calculated value.

G 4.4.8

Risk of accidents if the SLI is overridden!

Do not under any circumstances override the SLI. If the SLI is overridden, the crane operations will not be monitored and the truck crane will overturn if you leave the permissible working range.

Notes on two-hook operation

à Turning loads, p. 8 - 1.

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Notes on two-hook operation;

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4 - 93

Swing-away lattice 4.5 Tracing and eliminating malfunctions

4.5

Tracing and eliminating malfunctions

Malfunction

Cause

Remedy

Lifting limit switch switches off (lamp lights up)

Lifting limit switch not connected

Connect the lifting limit switch; p. 4 - 76.

The connection for the lifting limit switch on the main boom head is not overridden.

Override the lifting limit switch on the main boom head; p. 4 - 76.

N

à

à

There is a second lifting limit switch connected to the main boom and it is not locked.

For 12 m: There is no electrical connection between main boom head and section 1.

Make the electrical connecp. 4 - 68. tion;

The bridging plug is not inserted in the socket to the front of section 1.

Change over the bridging p. 4 - 69. plug;

For 21 m: There is no electrical connection between main boom head and section 1.

Make the electrical connection; p. 4 - 69.

There is no electrical connection between section 1 and section 2.

Make the electrical connection; p. 4 - 69.

The main boom cannot be telescoped with the rigged lattice extension

The main boom is at an impermissible angle.

Derrick the main boom to the required angle; p. 4 - 88.

The swing-away lattice cannot be derricked

The derricking gear of the swing-away lattice is switched off

Switch on the derricking gear of the swing-away lattice; p. 4 - 1.

à

The electrical connection has been broken.

Make the electrical connection; p. 4 - 68.

The hydraulic connection has been disconnected.

Make the hydraulic connection; p. 4 - 48.

The specified SLI code does not apply to operation with the lattice extension.

Enter the SLI code for operation with the swing-away lattice; p. 4 - 85.

The current load exceeds the derricking load – movement of the swing-away lattice is disabled. SLI error code 5 02 6 is displayed.

1. Raise the swing-away lattice.

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à

à

à à

à

à à

à

P once.

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

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2. Press button

Boom extension 5.1 Checklists for rigging work

5

Boom extension

5.1

Checklists for rigging work

5.1.1

CHECKLIST: Rigging the boom extension

H

This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by crossreferences.

Observe the warnings and safety instructions specified there!

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

à Operating

– Prior to crane operation, perform checks according to CHECKLIST: Operating manual.

Checks prior to crane operation;

à

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

– Roll the unused hoist rope onto the drum.

2. If the swing-away lattice is folded up at the side of the main boom, remove the swing-away lattice; p. 4 - 10.

à

3. Position hydraulic hoses for working with the lattice extension; p. 4 - 45.

à

4. Check whether the transport condition of the swing-away lattice has been established; Securing the swing-away lattice for transport when removed, p. 4 - 37.

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à

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5-1

Boom extension 5.1 Checklists for rigging work

5. Fold out deflection sheave on section 3, if necessary, fold out deflection sheave on section 4;

à p. 5 - 20.

6. Sling the necessary sections onto the auxiliary crane one after the other and install in front of the main boom.

Length of the boom extension in m 29

Section 3

Section 4

à p. 5 - 11

37

à p. 5 - 12

à

– Dimensions and weights p. 3 - 10, – Slinging sections p. 3 - 11.

à

7. Sling the swing-away lattice onto the auxiliary crane and fasten the guide ropes; slinging the swing-away lattice; p. 3 - 5.

à

8. While in the folded-up position, install the swing-away lattice in front of the last section of the boom extension; Installing/removing the swingaway lattice for the boom extension, p. 5 - 13.

à

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9. Fasten the guide ropes to section 2.

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Boom extension 5.1 Checklists for rigging work

10. Bring the Centre connection into position On section 1;

11. Swing section 2 in front of section 1; p. 4 - 62.

à p. 4 - 51.

à When rigging – section 2,

12. Establish the connection on the left-hand side between section 2 and Section 1 and section 2 fitted, p. 4 - 65. section 1;

à

13. Establish the electrical connection;

à p. 4 - 69.

14. Establish the hydraulic and electrical connections.

Boom extension in m

Hydraulic connection (electrical connection) 29 Main boom/section 3 Section 3/section 4

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For swing-away lattice

37

à p. 5 - 14 (à p. 5 - 17) à p. 5 - 15 (à p. 5 - 18) à p. 5 - 16 (à p. 5 - 19)

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5-3

Boom extension 5.1 Checklists for rigging work

15. Fold out deflection sheaves;

16. Position the hoist rope;

à p. 4 - 71.

à p. 5 - 22.

17. Reeve the hoist rope on the hook block; manual.

à GMK 6300L-1 operating

18. Install the lifting limit switch, attach the lifting limit switch weight and place it around the hoist rope; GMK 6300L-1 operating manual.

à

19. Install the anemometer and if necessary establish an electrical connecInstalling, p. 4 - 79. tion for the air traffic control light;

à

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

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Boom extension 5.1 Checklists for rigging work

21. Enter the current rigging mode with the rigged boom extension; Setting the SLI, p. 5 - 23.

à

Further steps with boom extension:

à

p. 5 - 24, – raise main boom; – telescope main boom; p. 5 - 25.

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à

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5-5

Boom extension 5.1 Checklists for rigging work

5.1.2

CHECKLIST: Unrigging the boom extension

H

This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by crossreferences.

Observe the warnings and safety instructions specified there!

Prerequisites: – An auxiliary crane is available.

1. Retract the main boom completely; lattice extension, p. 4 - 88.

2.

à telescoping with rigged heavy load

à

Derricking the swing– Raise the swing-away lattice completely; away lattice, p. 4 - 82.

– Lower the main boom into a horizontal position; p. 4 - 87.

à

3. Remove the lifting limit switch weight and lifting limit switch; Removing, p. 4 - 80.

à

4. Unreeve the hoist rope, remove it from the boom extension and roll it onto the drum up to the main boom head; Positioning/removing the hoist rope, p. 5 - 21.

à

à p. 4 - 72.

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5. Fold in the deflection sheaves at the front and rear;

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Boom extension 5.1 Checklists for rigging work

6. If necessary, disconnect the electrical connection of the air traffic control light and remove the anemometer; Removing, p. 4 - 80.

à

7. Disconnect the hydraulic and electrical connections: Boom extension in m

Hydraulic connection (electrical connection) 29 Main boom/section 3 Section 3/section 4 For swing-away lattice

37

à p. 5 - 14 (à p. 5 - 17) à p. 5 - 15 (à p. 5 - 18) à p. 5 - 16 (à p. 5 - 19)

8. Fasten the guide ropes to section 2.

9. If section 2 is to be removed:

à

p. 3 - 5.

– Sling section 2 onto the auxiliary crane; – Remove the locking pins between section 2 and section 1; p. 4 - 66.

– Set down section 2 on the separate vehicle.

à

After removing section 2, continue from point 13.

10. Remove the connection on the left-hand side between section 2 and section 1; Undoing the connection, p. 4 - 66.

à

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5-7

Boom extension 5.1 Checklists for rigging work

11. Swing section 2 so that it is aligned laterally to section 1 and bring the Centre connection into position Section 1/Section 2; When unrigging – section 2, p. 4 - 64, Section 1/section 2 position, p. 4 - 49.

à à

12. Sling the swing-away lattice onto the auxiliary crane and fasten the guide ropes; slinging the swing-away lattice; p. 3 - 5.

à

13. Remove the swing-away lattice while in the folded-up position; Removing, p. 5 - 13.

à

14. Sling all sections of the boom extension one after the other onto the auxiliary crane and remove them from the main boom.

Length of the boom extension in m 29

Section 3

à p. 5 - 11

37

Section 4

à p. 5 - 12

à

p. 3 - 10, – Dimensions and weights p. 3 - 11.

– Slinging sections

à

à Folding in,

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15. Fold in the deflection sheave on section 3, if necessary, fold in deflection sheave on section 4; p. 5 - 20.

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Boom extension 5.1 Checklists for rigging work

à p. 4 - 46.

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16. Position hydraulic hoses for working with the main boom;

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5-9

Boom extension 5.1 Checklists for rigging work

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Lattice extension operating manual GMK 6300L-1

Boom extension 5.2 Description of the rigging work

5.2

Description of the rigging work

5.2.1

Installing/removing sections

S

Risk of damage to connecting cables and hydraulic hoses!

Prior to removal, check that the electrical and hydraulic connections have been disconnected.

This prevents damage to the connecting cables and hydraulic hoses during removal.

Section 3 Installing

• (A) – Sling section 3, dimensions and

à

weights p. 3 - 10, slinging sections p. 3 - 11.

à

• Lift section 3 in front of the main boom head in such a way that the connecting points (2) align on both sides.

• Remove the pins from the holders (1).

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

• Carry out the procedure on the other side.

Removing

• (B) – Sling section 3, dimensions and weights à p. 3 - 10, slinging sections

à p. 3 - 11.

• Check whether the electrical and hydraulic connections have been disconnected; Hydraulic connections, p. 5 - 14, Electrical connections, p. 5 - 17.

à à

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

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

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• Carry out the procedure on the other side.

• Set down section 3.

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5 - 11

Boom extension 5.2 Description of the rigging work

Section 4 Installing

• (A) – Sling section 4, dimensions and

à

p. 3 - 10, slinging sections weights p. 3 - 11.

à

• Lift section 4 in front of the boom extension in such a way that the connecting points (2) align on both sides.

• Remove the pins from the holders (1).

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

• Carry out the procedure on the other side.

Removing

• (B) – Sling section 4, dimensions and weights à p. 3 - 10, slinging sections

à p. 3 - 11.

• Check whether the electrical and hydraulic connections have been disconnected; Hydraulic connections, p. 5 - 14, Electrical connections, p. 5 - 17.

à à

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

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

• Carry out the procedure on the other side.

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• Set down section 4.

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Boom extension 5.2 Description of the rigging work

5.2.2

Installing/removing the swing-away lattice for the boom extension

H

S

You can install a swing-away lattice either folded out or folded up.

Risk of damage to connecting cables and hydraulic hoses!

Prior to removal, check that the electrical and hydraulic connections have been disconnected.

This prevents damage to the connecting cables and hydraulic hoses during removal.

Installing

• (A) – Sling the swing-away lattice;

à p. 3 - 5.

• Lift the swing-away lattice in front of the boom extension in such a way that the connecting points (2) align on both sides.

• Remove the pins from the holders (1).

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

• Carry out the procedure on the other side.

Removing

• (B) – Sling the swing-away lattice; à p. 3 - 5.

• Check whether the electrical and hydraulic connections have been disconnected; Hydraulic connections, p. 5 - 14, Electrical connections, p. 5 - 17.

à à

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

• Insert the pins into the holders (1).

• Secure the pins using the retaining pins.

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• Carry out the procedure on the other side.

• Set down the lattice extension and check the transport condition;

à Securing the swing-away lattice for transport when removed, p. 4 - 37.

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5 - 13

Boom extension 5.2 Description of the rigging work

5.2.3

Hydraulic connections All connections are established via quick couplings. The allocation is ensured through the use of different shapes or sizes.

Main boom – section 3 Establishing the connection

• If necessary, bring the connections (1) into the position for working with the lattice p. 4 - 45. extension;

à

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

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

Disconnecting the connection

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

• Close the hose lines and the connections with the protective caps.

• Secure the hose lines (2) onto the holder (3)

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to prevent them from falling.

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Boom extension 5.2 Description of the rigging work

Section 3 – section 4 Establishing the connection

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

• Remove the protective caps and connect the hose lines (2) to the connections (3).

• Secure the hose lines (2) onto the holders (1) to ensure that they do not hang out during operation.

Disconnecting the connection

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

• Close the hose lines and the connections with the protective caps.

• Secure the hose lines (2) onto the holder (1) to prevent them from falling.

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5 - 15

Boom extension 5.2 Description of the rigging work

For swing-away lattice Establishing the connection

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

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

• Secure the hose lines (2) onto the holders (3) to ensure that they do not hang out during operation.

Disconnecting the connection

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

• Close the hose lines and the connections with the protective caps.

• Secure the hose lines (2) onto the holder (3)

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to prevent them from falling.

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Boom extension 5.2 Description of the rigging work

5.2.4

Electrical connections

Main boom – section 3

3

1

Establishing the connection

4

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

7

• Unwind the cable (7) from the holder (6).

2

• Remove the plug (4) from the dummy socket (5) and plug it into the socket (2).

5

6

• Wind up the cable (7) far enough onto the holder (6) so that it does not sag down.

Disconnecting the connection

• Remove the plug (4) from the socket (2) and plug it into the dummy socket (5).

• Wind the cable (7) onto the holder (6).

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

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5 - 17

Boom extension 5.2 Description of the rigging work

Section 3 – section 4 Establishing the connection

• Remove the protective cap from the socket (1).

• Unwind the cable (2) from the holder (5).

• Remove the plug (3) from the dummy socket (4) and plug it into the socket (1).

• Wind up the cable (2) far enough onto the holder (5) so that it does not sag down.

Disconnecting the connection

• Remove the plug (3) from the socket (1) and plug it into the dummy socket (4).

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

• Wind up the cable (2) far enough onto the

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holder (5) so that it does not sag down.

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Boom extension 5.2 Description of the rigging work

For swing-away lattice Establishing the connection

• Remove the protective cap from the socket (3).

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

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

• Wind up the cable (4) far enough onto the holder (5) so that it does not sag down.

Disconnecting the connection

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

• Wind up the cable (4) far enough onto the holder (5) so that it does not sag down.

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• Close the socket (3) with the protective cap.

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5 - 19

Boom extension 5.2 Description of the rigging work

5.2.5

Folding the deflection sheave in/out on section 3 and section 4 For folding the deflection sheave in and out on section 1;

à p. 4 - 71.

Folding out

• (A) – Remove the retaining pins from the pins (3).

• Hold the deflection sheave firmly by the handle (1) and pull out the pins (3).

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

• Secure the pins (3) using the retaining pins.

Folding in

• (A) – Remove the retaining pins from the pins (3).

• Hold the deflection sheave firmly by the handle (1) and pull out the pins (3).

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

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• Secure the pins (3) using the retaining pins.

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Boom extension 5.2 Description of the rigging work

5.2.6

G

Positioning/removing the hoist rope Risk of accidents due to falling parts!

In order to secure the hoist rope, always secure the sheaves and rods with retaining pins.

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

Possible reevings

1 sheave hook block and hook tackle Maximum lifting capacity of the hook block: 32 t Maximum lifting capacity of the hook tackle: 12 t Max. lifting capacity with the GMK 6300L-1 Reeving

Maximum lifting capacity

A 1 fall

10,5 t

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5 - 21

Boom extension 5.2 Description of the rigging work

Positioning/ removing the hoist rope

On the 29 m boom extension (A)

Positioning the hoist rope

• Remove the sheaves (1). Guide the hoist rope over the deflection sheaves

On the 37 m boom extension (B)

(6), (5), (4), (3) and over the head sheave (2) on section 1.

• Put all sheaves (1) back in place and secure them with retaining pins.

• Attach the hook tackle or the hook block. The hoist rope can only be reeved once on the boom extension;

Removing the hoist rope

à p. 5 - 21.

• Unreeve the hook block.

• Remove the sheaves (1).

• Take the hoist rope off the head sheave (2) and the deflection sheaves (5), (4), (3) and place it onto the ground on the left side.

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• Put all sheaves (1) back in place and secure them with retaining pins.

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Boom extension 5.3 Operation with boom extension

5.3

Operation with boom extension

H

G G

When operating with the boom extension, the maximum speed for the different power units is limited to 70%; GMK 6300L-1 operating manual.

à

Risk of overturning when operating with the boom extension!

A hook block must not be reeved on the main boom during operation with the boom extension.

It is prohibited to work with the main boom if the boom extension is rigged.

Risk of accidents due to overloading!

It is prohibited to lift a load with two hooks when the boom extension is rigged.

The raising, lowering, slewing, derricking and telescoping movements are carried out in the same way as when operating with the main boom.

This section only contains information that you will need additionally for a rigged boom extension.

5.3.1

Setting the SLI

Operation with boom extension

When operating with the boom extension, you must additionally enter the length of the swing-away lattice.

Setting the SLI

à Entering the SLI code, p. 4 - 85.

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A hook block must not be reeved on the main boom during operation with the boom extension.

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5 - 23

Boom extension 5.3 Operation with boom extension

5.3.2

G

Derricking the main boom Risk of accidents if the SLI is overridden!

Do not override the SLI when lowering the boom into a horizontal position.

If the SLI is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

If the following requirements are met and the slewing range is 360°, lowering into a horizontal position with the boom extension attached is permitted and monitored by the SLI. – The current rigging mode with the rigged boom extension is entered on the SLI, and the corresponding SLI code is displayed as per the Lifting capacity table.

– The current reeving on the boom extension is entered for the hoisting gear whose hoist rope is reeved on the boom extension.

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

– The main boom is fully retracted.

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When all of the above requirements have been satisfied, the SLI will automatically switch to the rigging tables and derricking is then permitted within the angle range that is below the working range of approx. 15°.

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Boom extension 5.3 Operation with boom extension

5.3.3

Telescoping with rigged boom extension

Slewing range of 360°

S

Risk of overloading of the main boom!

If you are telescoping the main boom with the rigged boom extension, you may not simultaneously slew the superstructure.

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

Telescoping will only be enabled by the SLI if the main boom is derricked to a certain angle and a maximum permissible load is not exceeded.

The required angle (between 75° and 80°) depends on the rigging mode of the truck crane.

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

If the main boom angle is too small for telescoping with the boom extension, the SLI displays an appropriate error message.

Span of 6.30 x 8.70 m

S

Risk of overturning backwards!

Given a span of 6.30 x 8.70 m and a lateral main boom position, telescoping is prohibited. There is a risk of overturning backwards.

Do not override the SLI. If the boom extension is rigged into position on the side, – raise the main boom, – slew the superstructure backwards into the 0° position and switch off the slewing gear, – telescope the main boom to the required length, – switch on the slewing gear and slew the superstructure to the side.

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If the main boom angle is too large for telescoping with the boom extension, the SLI displays an appropriate error message.

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5 - 25

Boom extension 5.3 Operation with boom extension

5.3.4

Information about the SLI shutdown Operation with the boom extension is monitored by the SLI. When operating with the boom extension, SLI shutdowns may occur for the same reasons as when operating with the main boom; GMK 6300L-1 operating manual.

à

Additional reasons for the occurrence of SLI shutdowns when operating with the boom extension can be found here; p. 4 - 91.

à

5.3.5

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 prevents the truck crane from overturning due to overloading.

• 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 GMK 6300L-1 operating manual.

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

• Immediately cease crane operation.

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

5.3.6

Information about two-hook operation Two-hook operation is prohibited if the boom extension is rigged; Turning loads, p. 8 - 1.

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à

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Auxiliary single-sheave boom top 6.1 Installing/removing

6

Auxiliary single-sheave boom top

6.1

Installing/removing

6.1.1

Installing/removing the auxiliary single-sheave boom top

Support

• (A) – Sling the auxiliary single-sheave boom top;

à p. 3 - 13.

• Pull out the pins (1) and (2).

• Hoist the auxiliary single-sheave boom top in front of the clamp.

• (B) – Align the auxiliary single-sheave boom top so that the bearing point lines up to the front bore holes in the clamp.

• Insert the pins (1) and (2) and secure each of them with a linchpin.

• Move the auxiliary single-sheave boom top into the transport position or working posiRigging the auxiliary single-sheave tion; boom top, p. 6 - 3.

à

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6-1

Auxiliary single-sheave boom top 6.1 Installing/removing

Removing

• Sling the auxiliary single-sheave boom top;

à p. 3 - 13.

(A) – In the transport position

• Pull out the pins (3) and (2).

(B) – In the working position

• Pull out the pins (1) to (4).

• Lift the auxiliary single-sheave boom top from the head of the main boom.

• Insert the pins (1) to (4) into the bearing points.

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• Secure all pins with linch pins.

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Auxiliary single-sheave boom top 6.2 Rigging the auxiliary single-sheave boom top

6.2

Rigging the auxiliary single-sheave boom top

6.2.1

Rigging in working position/transport position Working position

• (A) – Remove pins (1), (2) and (3).

• (B) – Swing the auxiliary single-sheave boom top in front of the main boom head.

• Insert the pins into the bearing points (4), (5) and (6) and secure them with linchpins.

Transport position

• (A) – Check if the pin (1) is inserted. If it is not fitted, fit it.

• Remove pins (2), (3) and (4).

• (B) – Swing the auxiliary single-sheave boom top onto the side of the main boom.

• Insert the pins into the bearing points (4), (5)

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and (6) and secure each of them with a linchpin.

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6-3

Auxiliary single-sheave boom top 6.2 Rigging the auxiliary single-sheave boom top

6.2.2

G

Attaching and removing hoist rope There is a 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, falling down and injuring people.

Positioning the hoist rope

• Remove the rods (1).

• Guide the hoist rope over the left head sheave of the main boom.

• Put all of the rods (1) back in place and secure them with retaining pins.

• Attach the hook tackle or the hook block.

Removing the hoist rope

• Unreeve the hook block.

• Remove the rods (1).

• Guide the hoist rope over the left head sheave of the main boom.

• Put all of the rods (1) back in place and secure them with retaining pins.

Possible reeving methods 1 sheave hook block and hook tackle Maximum load bearing capacity of the hook block: 32 t Maximum load bearing capacity of the hook tackle: 12 t

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Reeving

Maximum lifting capacity

A 1 fall

10,5 t

Lattice extension operating manual GMK 6300L-1

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Max. load bearing capacity with the GMK 6300L-1

Auxiliary single-sheave boom top 6.2 Rigging the auxiliary single-sheave boom top

6.2.3

Lifting limit switch and anemometer

Lifting limit switch

For operation For each reeved hoist rope, a lifting limit switch must be installed; Operating instructions GMK 6300L-1.

à

On the left side (A) – without a camera on the main boom (B) – with a camera on the main boom

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

• Remove the plug (4) from the dummy socket (6) and plug it into the socket (1).

• Wind the cable for plug (4) onto the holder (5).

• Install the lifting limit switch weight and lay

à Operating

it around the hoist rope; instructions GMK 6300L-1.

On the right side

If, additionally, a hook block is reeved on the main boom, connect the second lifting limit switch to the socket on the right side of the main boom Operating instructions GMK 6300L-1. head;

à

If no hook block is reeved on the main boom, the bridging plug must be plugged into the socket that is not used; Operating instructions GMK 6300L-1.

à

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6-5

Auxiliary single-sheave boom top 6.2 Rigging the auxiliary single-sheave boom top

For removal On the left side (A) – without a camera on the main boom (B) – with a camera on the main boom

• Remove the plug (5) from the socket (1).

• Insert the plug (5) into the dummy socket (6).

• Wind the cable for plug (5) onto the holder (4).

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

On the right side If no hook block is reeved on the main boom, the bridging plug must be Operating instructions plugged into the socket that is not used; GMK 6300L-1.

à

Anemometer

Installation and removal You must install the anemometer for operation with the auxiliary singlesheave boom top.

You must remove the anemometer for driving on-road.

It is installed and removed in the same way as for operation with the main Operating instructions GMK 6300L-1. boom;

à

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G

Risk of damage to the anemometer Remove the anemometer for on-road driving.

This prevents the anemometer from being damaged by wind (e.g. by suction currents caused by oncoming traffic in tunnels).

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Auxiliary single-sheave boom top 6.3 Operation with the auxiliary single-sheave boom top

6.3

Operation with the auxiliary single-sheave boom top

H

When operating the auxiliary single-sheave boom top, the maximum speed for the power units is not limited, GMK 6300L-1 operating manual.

à

The raising, lowering, slewing, derricking and telescoping movements 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 up auxiliary single-sheave boom top:

6.3.1

Setting the SLI • In addition, enter the following into the SLI: – the current rigging mode for operation with the main boom and

– the current reeving at the auxiliary single-sheave boom top for the hoist whose hoist rope is switched to the auxiliary single-sheave boom top.

The loads specified in the lifting capacity tables are reduced during operation with the auxiliary single-sheave boom top if: – a hook block is reeved in on the main boom, or – the swing-away lattice is folded to the side on the main boom.

The values which must be deducted from the load capacities depend on the length of the swing-away lattice and the weight of the hook block. You will find a table with the values in the lifting capacity tables in the section Information on working with the swing-away lattice extension. The SLI switches off correspondingly earlier.

6.3.2

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G

Derricking, telescoping the main boom Risk of accidents if the SLI is overridden!

Do not override the SLI when lowering the boom into a horizontal position.

If the SLI is overridden, the crane operations will not be monitored and the truck crane will overturn if you leave the permissible working range.

The requirements that must be satisfied before the raising, setting and telescoping of the main boom with rigged auxiliary single-sheave boom top are permitted for a slewing range of 360° are monitored by the SLI; GMK 6300L-1 operating manual – Crane operation.

à

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6-7

Auxiliary single-sheave boom top 6.3 Operation with the auxiliary single-sheave boom top

6.3.3

Information about the SLI shutdown Operation with the auxiliary single-sheave boom top is monitored by the SLI. When operating with the lattice extension, SLI shutdowns may occur for the same reasons as when operating with the main boom; GMK 6300L-1 operating manual.

à

6.3.4

G

Procedure if permissible wind speeds are exceeded Risk of accidents due to excessively high wind speeds!

If the current wind speed is higher that the maximum permissible wind speed, stop crane operation immediately and set up the corresponding rigging mode.

This prevents the truck crane from overturning due to overloading.

• Prior to and during crane operation, check whether the actual 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 GMK 6300L-1 operating manual.

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

• Immediately stop crane operation.

• Bring 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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Auxiliary single-sheave boom top 6.3 Operation with the auxiliary single-sheave boom top

6.3.5

SLI display with the auxiliary single-sheave boom top folded up/rigged If the auxiliary single-sheave boom top on the main boom is fitted in the working position or the transport position, the lifting capacities listed in the Lifting capacity tables are lower.

The Maximum load display (1) does not show the reduced values.

However, the SLI takes into account the value for the currently fitted auxiliary single-sheave boom top, adds the weight of the raised load and displays the sum on the Current load display (2). The SLI switches off correspondingly earlier.

6.3.6

Notes on two-hook operation

à Turning loads, p. 8 - 1.

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Notes on two-hook operation;

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Auxiliary single-sheave boom top 6.3 Operation with the auxiliary single-sheave boom top

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Heavy load lattice extension 7.1 Checklists for rigging work

7

Heavy load lattice extension

7.1

Checklists for rigging work

7.1.1

CHECKLIST: Installing the heavy load lattice extension

H

This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by cross-references.

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is on outriggers or the main boom is on the boom rest.

– The heavy load lattice extension is in transport condition;

à p. 7 - 7.

– An auxiliary crane is available.

2. – Sling the heavy load lattice extension and attach guide rope; Identification and slinging point, p. 3 - 15.

à

– Fix the heavy load lattice extension on the main boom head; p. 7 - 7.

à

– Remove the sling gear.

3. Swing the heavy load lattice extension on to the side of the main boom; p. 7 - 9.

à

or:

à p. 7 - 10.

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Swing the heavy load lattice extension in working position;

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7-1

Heavy load lattice extension 7.1 Checklists for rigging work

7.1.2

CHECKLIST: Removing the heavy load lattice extension

H

This checklist is not a complete set of operating instructions. There are accompanying operating instructions which are referred to by cross-references.

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is on outriggers or the main boom is on the boom rest.

– An auxiliary crane is available.

– An 8°angle is set;

à p. 7 - 13.

2. Sling the heavy load lattice extension and attach guide rope; Identification and slinging point, p. 3 - 15.

à

3. Swing the heavy load lattice extension on to the side of the main boom; p. 7 - 9.

à

4. Lift the heavy load lattice extension and put it onto the transport vehicle.

– For lifting;

à p. 7 - 8.

5. Check the transport condition of the heavy load lattice extension; p. 7 - 7.

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à

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Heavy load lattice extension 7.1 Checklists for rigging work

7.1.3

CHECKLIST: Rigging the heavy load lattice extension 1. Prerequisite – The heavy load lattice extension is fitted to the side of the main boom CHECKLIST: Installing the heavy load or is in its working position; lattice extension, p. 7 - 1.

à

2. If the heavy load lattice extension is installed in its working position, this point is not required.

– Swing the heavy load lattice extension in working position; p. 7 - 10.

à

3. If necessary, set the angle of the heavy load lattice extension; p. 7 - 13.

à

4. Position the hoist rope;

5. Reeve the hook block;

à p. 7 - 15.

à GMK 6300L-1 operating manual.

6.Install lifting limit switch;

à p. 7 - 17.

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7-3

Heavy load lattice extension 7.1 Checklists for rigging work

7. Install anemometer and, if necessary, air traffic control light; p. 7 - 17.

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à

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Heavy load lattice extension 7.1 Checklists for rigging work

7.1.4

CHECKLIST: Unrigging the heavy load lattice extension 1. Prerequisite – The heavy load lattice extension is fitted to the side of the main boom CHECKLIST: Installing the heavy load or is in its working position; lattice extension, p. 7 - 1.

à

2. Remove anemometer and, if necessary, the air traffic control light; p. 7 - 17.

à

3. Unreeve the hook block;

à GMK 6300L-1 operating manual.

4.Remove the lifting limit switch;

5. Remove the hoist rope;

à Lifting limit switch, p. 7 - 17.

à p. 7 - 16.

6. Set 8° angle, if necessary;

à p. 7 - 13.

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7-5

Heavy load lattice extension 7.1 Checklists for rigging work

7. If necessary, swing the heavy load lattice extension on to the side of the main boom; p. 7 - 9.

à

à CHECKLIST:

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8. If the heavy load lattice extension is to be removed; Removing the heavy load lattice extension, p. 7 - 2.

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Heavy load lattice extension 7.2 Description of rigging work

7.2

Description of rigging work

7.2.1

Transport condition The heavy load lattice extension must be in the transport position before rigging and during transport.

• Check that the heavy lattice load extension is secure for transport or secure now, if necessary.

– All pins (1) must be secured in the clamps.

– The 8° angle for transport has been set.

– The chain hoist (2) is tensioned such that it cannot come loose during transport.

– The cable for the lifting limit switch is wound up on the holder (4).

– The lifting limit switch plug is in the dummy socket (3).

7.2.2

Fixing/releasing the heavy load lattice extension

Fixing

• Lift the heavy load lattice extension with the auxiliary crane next to the main boom head.

• Align the connection points (4).

• Insert the pins for the clamps (3) into the connecting points (4).

• Align the connection point (1).

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

• Secure all pins in place using retaining pins.

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7-7

Heavy load lattice extension 7.2 Description of rigging work

Releasing

• Secure the heavy load lattice extension with the auxiliary crane.

• Take the load off of the connecting point (1).

• Plug the pin for the connecting point (1) into the holder (2).

• Take the load off of the connecting points (4).

• Put the connecting point pins (4) into the holders (3).

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• Secure all pins in place using retaining pins.

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Heavy load lattice extension 7.2 Description of rigging work

7.2.3

Slewing the heavy load lattice extension

To swing against the side of the main boom

Requirements: – The truck crane is on outriggers or the main boom has been placed on the boomsupport.

– Heavy load lattice extension in working position.

– Heavy load lattice extension is at an angle of 8°.

– The hoist rope is unreeved.

• Attach a guide rope.

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

• Put the pins into the holders (2) and secure them with retaining pins.

• Swing the heavy load lattice extension onto the main boom until the bearing points (1) are aligned.

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7-9

Heavy load lattice extension 7.2 Description of rigging work

• Take the pins from the holder (2).

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

• Remove the guide rope.

The heavy load lattice extension is now swung against the side of the main boom.

To swing into working position

Requirements: – The truck crane is on outriggers or the main boom has been placed on the boomsupport.

– The heavy load lattice extension is swung against the side of the main boom.

– The hoist rope is unreeved.

– The required counterweight has been rigged.

• Attach a guide rope.

• Pull the pin out of the bearing point (2).

• Insert the pin into the holder (1) and secure

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it with a retaining pin.

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Heavy load lattice extension 7.2 Description of rigging work

• Swing the heavy load lattice extension onto the main boom until the bearing points (1) are aligned.

• Remove the pins from the holders (1).

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

• Detach the guide rope from the rope attachment point.

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The heavy load lattice extension is now in working position.

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7 - 11

Heavy load lattice extension 7.2 Description of rigging work

7.2.4

To set the angle Depending on requirements, the heavy load lattice extension can be operated at two different angles.

Installing/removing the chain hoist

G

(A)

8° angle, (to secure for transport)

(B)

30° angle

Only use the chain hoist supplied to set the angle.

Risk of accidents from uncontrolled movements When removing the chain hoist, the heavy load lattice extension must be set at an angle of 8° or 30°. This prevents the heavy load lattice extension from folding down in an uncontrolled manner and injuring or even killing you or others standing nearby.

Installing • Attach the chain hoist at slinging points (1) and (2).

Removing The heavy load lattice extension is set at a 8° or 30° angle.

• Loosen the chain hoist.

• Fit the chain hoist to the slinging points (1)

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and (2).

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Heavy load lattice extension 7.2 Description of rigging work

To set the angle

• Hook in the chain hoist; à Installing/removing the chain hoist, p. 7 - 12.

• Lift the heavy load lattice extension with the chain hoist until the load on pin (1) is relieved.

• Remove the bolts (1) from the bearing points.

• Lift the heavy load lattice extension or lower it.

(A)

For 8° angle: Lift the heavy load lattice extension to its full extent.

(B)

For 30° angle: Lower the heavy load lattice extension as far as it will go.

• Insert the pins (1) back into the bearing point and secure them all with retaining pins.

• Remove the chain hoist.

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S

Risk of uncontrolled movements When setting the 30° angle, always lower the heavy load lattice extension as far as it will go and insert the pins back into the bearing point. This way, you can prevent the heavy load lattice extension from being in a non-permissible position without a fall-back guard.

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7 - 13

Heavy load lattice extension 7.2 Description of rigging work

7.2.5

Positioning/removing the hoist rope

Possible reeving methods

Reeving the hoist rope into the hook block; à GMK 6300L-1 operating manual.

3 sheave hook blocke Maximum load bearing capacity of the hook block: 80 t Max. load bearing capacity with the GMK 6300L-1 Reeving

Maximum lifting capacity

A

41.7 t

4 fall

1 sheave hook blocke Maximum load bearing capacity of the hook block: 32 t Max. load bearing capacity with the GMK 6300L-1 Reeving

Maximum lifting capacity

3 fall

31,4 t

B

2 fall

21,0 t

C

1 fall

10,5 t

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A

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Heavy load lattice extension 7.2 Description of rigging work

Hook tackle Maximum load bearing capacity of the hook tackle: 12 t Max. load bearing capacity with the GMK 6300L-1 Reeving

Maximum lifting capacity

A

10.5 t

1 fall

Positioning the hoist rope

• Pull out the rods (1) and (4).

• Feed the hoist rope through under the rope grab.

• Feed the hoist rope over the upper head sheave (2) and over the head sheave (3).

• Reeve the hoist rope with the required number of runs; p. 7 - 14.

à Possible reeving methods,

• If there are even number of runs, fasten the fork element to the fixed point(5) and for an odd number of lines, fasten it to the hook block.

• Insert the rods (1) and (4) and secure them with the retaining pins.

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7 - 15

Heavy load lattice extension 7.2 Description of rigging work

• Fasten the lifting limit switch weight (2) to the lifting limit switch (1).

• Place the lifting limit switch weight around the hoist rope – ensure that the safety pin (3) snaps in properly.

The lifting limit switch (1) may not be disabled;

à GMK 6300L-1 operating manual.

Removing the hoist rope

• Remove the lifting limit switch weight.

• Pull out the rods (1) and (2).

• Unreeve the hoist rope and feed it back.

• Put the rods (1) and (2) back and secure

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them with the retaining pins.

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Heavy load lattice extension 7.2 Description of rigging work

7.2.6

Lifting limit switch and anemometer

Lifting limit switch

For operation For each reeved hoist rope, a lifting limit switch must be installed;

à Operating instructions GMK 6300L-1.

On the left side (A) – without a camera on the main boom (B) – with a camera on the main boom

• Install the lifting limit switch on holder (7);

à GMK 6300L-1 operating manual.

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

• Remove the plug (4) from the dummy socket (6) and plug it into the socket (1).

• Wind the cable for plug (4) onto the holder (5).

• Install the lifting limit switch weight and lay

à Operating

it around the hoist rope; instructions GMK 6300L-1.

On the right side

If, additionally, a hook block is reeved on the main boom, connect the second lifting limit switch to the socket (1) on the right side of the main boom Operating instructions GMK 6300L-1. head;

à

If no hook block is reeved on the main boom, the bridging plug (2) must be plugged into the unused socket; Operating instructions GMK 6300L-1.

à

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7 - 17

Heavy load lattice extension 7.2 Description of rigging work

For removal On the left side (A) – without a camera on the main boom (B) – with a camera on the main boom

• Remove the plug (5) from the socket (1).

• Insert the plug (5) into the dummy socket (6).

• Wind the cable for plug (5) onto the holder (4).

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

• Remove the lifting limit switch (7) from the holder;

à GMK 6300L-1 operating manual.

On the right side If no hook block is reeved on the main boom, the bridging plug (1) must be plugged into the unused socket; Operating instructions GMK 6300L-1 operating manual.

à

Anemometer

Installation and removal You must install the anemometer for operation with the heavy load lattice extension.

You must remove the anemometer for driving on-road.

It is installed and removed in the same way as for operation with the main boom; GMK 6300L-1 operating manual.

à

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G

Risk of damage to the anemometer Remove the anemometer for on-road driving.

This prevents the anemometer from being damaged by wind (e.g. by suction currents caused by oncoming traffic in tunnels).

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Heavy load lattice extension 7.3 Operation with the heavy load lattice extension

7.3

Operation with the heavy load lattice extension The raising, lowering, slewing, derricking and telescoping movements 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.

7.3.1

Setting the SLI • In addition, enter the following into the SLI: – the current rigging mode for operation with the heavy load lattice extension and

– The current reeving on the heavy load lattice extension is entered for the hoisting gear whose hoist rope is reeved on the heavy load lattice extension.

The loads specified in the lifting capacity tables will be reduced during operation with the heavy load lattice extension if: – a hook block is reeved in on the main boom, or – the swing-away lattice is folded to the side on the main boom.

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The values which must be deducted from the load capacities depend on the length of the swing-away lattice and the weight of the hook block. You will find a table with the values in the lifting capacity tables in the section Information on working with the swing-away lattice extension. The SLI will switch off correspondingly earlier.

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7 - 19

Heavy load lattice extension 7.3 Operation with the heavy load lattice extension

7.3.2

Derricking, telescoping the main boom

Slewing range of 360°

G

Risk of accidents if the SLI is overridden!

Do not override the SLI when lowering the boom into a horizontal position.

If the SLI is overridden, the crane operations will not be monitored and the truck crane will overturn if you leave 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 SLI; GMK 6300L-1 operating manual.

à

If the main boom is set to a steep angle and if the heavy load lattice extension is at 8°, the hook block may hit the main boom. When the minimum permitted working radius has been reached, the SLI will prevent the boom being raised further.

Telescoping with span of 6.30 x 8.70 m or 5.00 x 8.70 m

S

Risk of overturning backwards!

Given a span of 6.30 x 8.70 m or 5.00 x 8.70 m and a lateral main boom position, telescoping is prohibited. There is a risk of overturning backwards.

Do not override the SLI. If the heavy load lattice extension is rigged into position on the side, – raise the main boom, – slew the superstructure backwards into the 0° position and switch off the slewing gear, – telescope the main boom to the required length, – switch on the slewing gear and slew the superstructure to the side.

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If the main boom angle is too large for telescoping with the heavy load lattice extension, the SLI displays an appropriate error message.

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Heavy load lattice extension 7.3 Operation with the heavy load lattice extension

7.3.3

Information about the SLI shutdown Operation with the heavy load lattice extension is monitored by the SLI. When operating with the lattice extension, SLI shutdowns may occur for the GMK 6300L-1 same reasons as when operating with the main boom; operating manual.

à

7.3.4

G

Procedure if permissible wind speeds are exceeded Risk of accidents due to excessively high wind speeds!

If the current wind speed is higher that the maximum permissible wind speed, stop crane operation immediately and set up an appropriate rigging mode.

This prevents the truck crane from overturning due to overloading.

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

• Make sure that you follow the instructions for checking the wind speed;

à GMK 6300L-1 operating manual.

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

• Immediately stop crane operations.

• Bring 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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7 - 21

Heavy load lattice extension 7.3 Operation with the heavy load lattice extension

7.3.5

SLI display with the heavy load lattice extension folded up/ rigged If the heavy load lattice extension on the main boom is in its working position or is mounted on the side of the main boom, the lifting capacities listed in the Lifting capacity tables are reduced.

The Maximum load display (1) does not show the reduced values.

However, the SLI takes into account the value for the heavy load lattice extension fitted, it adds the weight of the raised load and displays the sum on the Current load display (2). The SLI will switch off correspondingly earlier.

7.3.6

Notes on two-hook operation

à Turning loads, p. 8 - 1.

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Notes on two-hook operation;

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Turning loads 8.1 Prerequisites

8

Turning loads Two-hook operation is required to turn loads.

Two-hook operation is permissible only with: – Swing-away lattice or – Auxiliary single-sheave boom top or – Heavy load lattice extension.

G H H 8.1

Risk of accidents due to overloading Lifting a load with two hooks is permitted only if the following instructions and illustrations are observed.

If these instructions are disregarded, accidents can occur due to individual parts of the truck crane being overloaded. The SLI then no longer provides protection.

For the position and function of the necessary operating elements; Operating instructions GMK 6300L-1.

à

In two-hook operation, the loads given in the Lifting capacity table are reduced by the weight of both reeved hook blocks.

Prerequisites The following description requires that: – the main hoist rope is reeved on the main boom; – the auxiliary hoist rope is reeved on the lattice extension, – the lifting limit switches for both hoists are connected, – the reeving on the main boom is the same or greater than the reeving on the lattice extension and

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– the SLI code is set according to the Lifting capacity table for the actual rigging status of the truck crane with the rigged lattice extension.

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8-1

Turning loads 8.2 Setting the SLI

8.2

Setting the SLI For two-hook operation, on the SLI you must: – enter the current reeving for the main and auxiliary hoist.

The values are stored and opened directly when switching hoists.

– Switch on operation with both hoists in such a way that the digit for the auxiliary hoist lights up on the Hoists display.

Entering the reeving If the symbol (1) is shown without digits on the reeving input, you must switch input mode on:

• Press the button next to symbol (1) once.

Input mode is switched on if symbol (1) is highlighted in green. A digit that displays which hoist the reeving applies to appears next to symbol (1).

Digit I: Main hoist Digit II:

Auxiliary hoist

• Enter the current number of lines (2) of the reeved hoist rope for the displayed hoist ( 8 9 ), e.g. 09, for the main hoist.

• Press the button next to the symbol (1) repeatedly until the digit for the other hoist is displayed (e.g. II for the auxiliary hoist).

• Enter the current number of lines (2) of the reeved hoist rope for the displayed hoist ( 8 9 ), e.g. 02 for the auxiliary hoist.

Now the reeving has been entered for both hoists.

The SLI always takes the reeving entered for the hoist that is displayed at the Hoists indicator lamps into account. For turning loads, the SLI must take the auxiliary hoist and its reeving into account and both hoists must be switched on. To access this SLI setting, proceed as follows:

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Setting the SLI to the auxiliary hoist

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Turning loads 8.2 Setting the SLI

Switch off both hoists • Press button (1) and then (2).

– The lamps in buttons (1) and (2) are glowing weakly.

– Symbol (3) is red when the main hoist is switched off.

– Symbol (4) is red when the auxiliary hoist is switched off.

Switching on the auxiliary hoist • Press the button (1) once.

– The lamp in button (1) lights up brightly.

– Symbol (2) is green when the auxiliary hoist is switched on.

At the Hoists display, lamp II for the auxiliary hoist now lights up.

Switching on the main hoist • Press the button (1) once.

– The lamp in button (1) lights up brightly.

– Symbol (2) is green when the main hoist is switched on.

On the hoists display, lamp I for the main hoist is now also flashing.

• On the SLI, select the current rigging mode with the rigged lattice extension or enter the appropriate SLI code according to the lifting capacity table.

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The SLI is now set for two-hook operation. It now takes into account: – the reeving for the auxiliary hoist, – the lifting capacity tables for the lattice extension.

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8-3

Turning loads 8.3 Turning a load

8.3

Turning a load

S H

Carry out the load turning only as it is described in this section.

Risk of accidents due to overloading Keep the acceleration forces as low as possible during two-hook operation.

For this reason, move the load at the lowest possible speed.

As soon as the load is on two hooks, there will be slight differences in the Current load display. However, these deviations are still on the safe side as regards an SLI shutdown.

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In principle, turning loads with the auxiliary single-sheave boom top or heavy load lattice extension is performed as for turning load with the swingaway lattice, shown below.

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Turning loads 8.3 Turning a load

• (A) – First, only sling the load to the hook block of the lattice extension (rope of the auxiliary hoist).

• Lift the load fully with the lattice extension.

• (B) – Only now should you attach the load to the hook block of the main boom as well (main hoist rope).

• (A) – Now lift the load with the hook block on the main boom until both slinging points are at the same height.

• (B) – Slacken the hoist rope on the lattice extension until the load is only hanging from the hook block on the main boom.

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The load has now been turned.

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8-5

Turning loads 8.3 Turning a load

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Driving with a rigged crane 9.1 Safety instructions

9

Driving with a rigged crane

9.1

Safety instructions

Risk of overturning due to superstructure slewing When driving the rigged truck crane, the slewing gear must be switched off.

Risk of accidents when driving on public roads!

Driving on public streets is only permitted when all items on the CHECKGMK 6300L-1 operating LIST: Checks before on-road driving are fulfilled; manual.

Driving on public roads with a rigged truck crane is not permitted.

à

Danger of tipping when driving the rigged truck crane Driving with a rigged truck crane is an operating mode which must be carried out with the utmost care. For this reason, make sure that you observe the listed safety instructions in the relevant sections of the GMK 6300L-1 operating manual.

Risk of accidents due to swinging hook block/load!

Secure the hook block/load when driving so that it cannot swing.

Start to drive slowly so that the hook block/load does not swing.

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G G G G G

Risk of accidents if your view of the truck crane is partially obstructed!

While driving, always stay in visual or radio contact with a banksman who can observe the parts which you cannot see.

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9-1

Driving with a rigged crane 9.2 Driving distance

9.2

Driving distance The driving distance must be even. Uneven surfaces cannot be compensated with the level adjustment system.

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

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

9.3

Rigging mode and axle loads

Driving without load

• Move the main boom and the lattice extension into the prescribed position;

à Tables with boom positions and axle loads, p. 9 - 5.

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

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

S

Risk of damage to the axle lines!

Always move the main boom and the lattice extension to the specified position before you drive the rigged truck crane. Boom positions which deviate from the specified position can result in impermissible loads on the axle lines.

It is not permitted to drive with a load on the lattice extension built up in front.

Table with axle loads

The axle loads specified in the tables refer to a driving mode with the basic unit.

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Driving with load

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Driving with a rigged crane 9.4 Before driving the rigged truck crane

9.4

Before driving the rigged truck crane • Check the tyre pressure and the wind speed;

à GMK 6300L-1 operating manual.

• Switch off the slewing gear; à GMK 6300L-1 operating manual.

• Place the truck crane on the wheels; à GMK 6300L-1 operating manual.

The suspension is switched off.

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

9.5

Driving the rigged truck crane

Driving from the driver's cab

• Engage the lowest starting gear; à GMK 6300L-1 operating manual. In this way you prevent the gears changing up and ensure that the speed is kept to a minimum.

• Switch on the separate steering; à GMK 6300L-1 operating manual.

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

While driving

G

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

• Only drive slowly, do not change up.

• The turning radius should be as large as possible when driving around corners!

• Steer the truck crane only when it is rolling and avoid sudden steering movements.

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9-3

Driving with a rigged crane 9.5 Driving the rigged truck crane

S G

Risk of damage to the steering linkage!

The steering linkage can be damaged if the steering is operated while the vehicle is stationary.

Danger of overturning when switching on the suspension!

The suspension must be deactivated (locked) as long as the rigged truck crane is on wheels.

When switching on the suspension, the suspension cylinders would suddenly be pressed together and damaged, and the truck crane could overturn.

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

9-4

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Driving with a rigged crane 9.6 Tables with boom positions and axle loads

9.6

Tables with boom positions and axle loads

Information about the tables

The axle loads specified in the tables refer to a driving mode with the basic unit.

H

The specified maximum axle load is only reached at the limits of the stated angle range for the main boom, e.g. with 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 stated angle range.

The following applies to the foot notes in the table: 1)

indicated slewing angle 0°

front:

indicated slewing angle 180°

front:

on the 1st and 2nd axle line

rear:

on the 3rd, 4th, 5th and 6th axle line

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2)

rear:

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9-5

Driving with a rigged crane 9.6 Tables with boom positions and axle loads

9.6.1

Swing-away lattice

12 m swing-away lattice

All the axle loads in the following table apply for a 32 t hook block (weight: 620 kg) reeved on the lattice extension.

Counterweight in t

Telescope status

I-II-III-IV-V-VI in %

Main boom Lattice angle extension in ° inclination in °

SuperMaximum axle load2) structure in t position1) front rear

50-50-0-0-0-0

20 - 40

0 -20

front

17.5

22.0

0-0-0-0-0-0

75 - 80

0 - 40

rear

14.0

21.5

100-0-0-0-0-0

20 - 35

0 - 20

front

17.0

24.0

0-0-0-0-0-0

70 - 80

0 - 40

rear

16.5

23.5

100-0-0-0-0-0

20

0 - 20

front

13.5

25.5

0-0-0-0-0-0

65 - 80

0 - 40

rear

19.0

25.5

74.53)

0-0-0-0-0-0

75 - 80

0 - 40

rear

24.0

26.5

92.53)

0-0-0-0-0-0

80

40

rear

28.0

28.0

35.5

45

54.5

1) 2)

,

Counterweight combination set down on the counterweight platform

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3)

à Information about the tables, p. 9 - 5

9-6

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Lattice extension operating manual GMK 6300L-1

Driving with a rigged crane 9.6 Tables with boom positions and axle loads

21 m swing-away lattice

Counterweight in t

All the axle loads in the following table apply for hook tackle (weight 300 kg) reeved on the lattice extension.

Telescope status

I-II-III-IV-V-VI in %

Main boom Lattice angle extension in ° inclination in °

Maximum axle load2) Superin t structure position1) front rear

50-0-0-0-0-0

20 - 30

0 - 20

front

13.0

22.5

0-0-0-0-0-0

75 - 80

0 - 40

rear

14.0

22.5

100-0-0-0-0-0

20 - 40

0 - 20

front

19.0

24.0

0-0-0-0-0-0

75 - 80

0 - 40

rear

16.5

23.5

100-0-0-0-0-0

20 - 25

0 - 20

front

15.5

25.5

0-0-0-0-0-0

70 - 80

0 - 40

rear

18.5

25.5

74.53)

0-0-0-0-0-0

80

0 - 40

rear

24.0

26.0

92.53)

0-0-0-0-0-0

80

20

rear

28.0

28.0

35.5

45

54.5

1), 2)

Counterweight combination set down on the counterweight platform

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3)

à Information about the tables, p. 9 - 5

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9-7

Driving with a rigged crane 9.6 Tables with boom positions and axle loads

9.6.2

Boom extension

29 m boom extension

All the axle loads in the following table apply for hook tackle (weight 300 kg) reeved on the lattice extension.

Counterweight in t

Telescope status

I-II-III-IV-V-VI in %

Main boom Lattice angle extension in ° inclination in °

SuperMaximum axle load2) structure in t position1) front rear

100-0-0-0-0-0

20 - 40

0 - 20

front

21.5

23.0

0-0-0-0-0-0

75 - 80

0 - 40

rear

16.0

24.0

100-0-0-0-0-0

20 - 35

0 - 20

front

18.0

26.0

0-0-0-0-0-0

70 - 80

0 - 40

rear

18.5

26.0

74.53)

0-0-0-0-0-0

75 - 80

0 - 40

rear

23.5

27.5

92.53)

0-0-0-0-0-0

80

0

rear

28.0

28.0

45

54.5

1) 2)

,

Counterweight combination set down on the counterweight platform

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3)

à Information about the tables, p. 9 - 5

9-8

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Driving with a rigged crane 9.6 Tables with boom positions and axle loads

37 m boom extension

Counterweight in t

45

54.5 74.53)

All the axle loads in the following table apply for hook tackle (weight 300 kg) reeved on the lattice extension.

Telescope status

I-II-III-IV-V-VI in %

Main boom Lattice angle extension in ° inclination in °

Maximum axle load2) Superin t structure position1) front rear

50-50-0-0-0-0

20 - 40

0 - 20

front

22.5

23.0

0-0-0-0-0-0

80

0 - 40

rear

15.5

23.5

50-50-0-0-0-0

20 - 30

0 - 20

front

19.0

25.0

0-0-0-0-0-0

80

0 - 40

rear

18.0

24.5

0-0-0-0-0-0

80

0 - 40

rear

23.0

27.0

1), 2)

Counterweight combination set down on the counterweight platform

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3)

à Information about the tables, p. 9 - 5

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9-9

Driving with a rigged crane 9.6 Tables with boom positions and axle loads

9.6.3

Heavy load lattice extension All the axle loads in the following table apply for a 80 t hook block (weight: 1 125 kg) reeved on the lattice extension.

Telescope status

I-II-III-IV-V-VI in %

Main boom Lattice angle extension in ° inclination in °

SuperMaximum axle load2) structure in t position1) front rear

0-0-0-0-0-0

15 - 45

8

front

14.0

14.0

0-0-0-0-0-0

15 - 50

30

front

14.0

14.5

0-0-0-0-0-0

15 - 40

8

front

11.5

16.0

0-0-0-0-0-0

15 - 40

30

front

11.5

16.0

0-0-0-0-0-0

80

30

rear

7.0

16.5

50-0-0-0-0-0

15 - 40

8

front

17.0

17.0

50-0-0-0-0-0

15 - 45

30

front

17.0

17.5

0-0-0-0-0-0

80

30

rear

9.5

18.0

50-0-0-0-0-0

15 - 40

8

front

15.0

19.0

50-0-0-0-0-0

15 - 40

30

front

15.0

19.0

0-0-0-0-0-0

80

30

rear

11.0

18.5

50-0-0-0-0-0

15 - 30

8

front

13.5

19.5

50-0-0-0-0-0

15 - 30

30

front

13.5

19.5

0-0-0-0-0-0

75 - 80

30

rear

12.0

20.0

100-0-0-0-0-0

15 - 40

8

front

19.0

21.5

100-0-0-0-0-0

15 - 40

30

front

19.0

21.5

0-0-0-0-0-0

70 - 80

30

rear

14.5

21.5

100-0-0-0-0-0

15 - 30

8

front

15.5

24.0

100-0-0-0-0-0

15 - 30

30

front

15.5

24.0

0-0-0-0-0-0

65 - 80

30

rear

16.5

23.5

100-50-50-50-50-50

35 - 45

8

front

22.5

24.0

50-50-50-0-0-0

15 - 20

30

front

14.0

25.5

0-0-0-0-0-0

60 - 80

30

rear

19.0

25.5

74.53)

0-0-0-0-0-0

70 - 80

30

rear

24.5

26.5

92.53)

0-0-0-0-0-0

75

30

rear

27.5

28.0

0

7.0

16.5

21.2

26.0

35.5

45.0

54.5

1) 2)

,

3)

9 - 10

à Information about the tables, p. 9 - 5

Counterweight combination set down on the counterweight platform

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Lattice extension operating manual GMK 6300L-1

12.03.2018

Counterweight in t

Driving with a rigged crane 9.6 Tables with boom positions and axle loads

9.6.4

Auxiliary single-sheave boom top • When driving with a rigged auxiliary single-sheave boom top, proceed in

à GMK 6300L-1

12.03.2018

the same way as for driving with a rigged truck crane; operating manual.

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9 - 11

Driving with a rigged crane 9.6 Tables with boom positions and axle loads

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Blank page

9 - 12

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Lattice extension operating manual GMK 6300L-1

Maintenance 10.1 Cleaning

10

Maintenance

H

Observe general notes and the information on safety and environmental protection in the Maintenance manual.

In this chapter you will find the information required for the maintenance of the lattice extensions.

– Maintenance intervals as in the Maintenance manual of the truck crane delivered, observe factors that could shorten the intervals.

– Run-in regulations for the lattice extensions are not intended.

– Periodic inspections are not intended.

10.1

Cleaning

H

Follow the instructions for cleaning work with high-pressure cleaners in the Maintenance manual.

• Provide protection for the following electrical parts during cleaning work: 1 Potentiometer in the joint of section 1

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2 Switch box at the rear of section 1 3 Switch box at the front of section 1 4 Switch box at the front of section 2

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10 - 1

Maintenance 10.2 Maintenance plans

10.2

Maintenance plans

10.2.1

Maintenance plan M 1

M1

Maintenance work on the LATTICE EXTENSION: monthly/after 100 oper. hrs.

Swing-away lattice – lubricating pins – Grease the slide faces at the front connection

à p. 10 - 3 à p. 10 - 4

Boom extension

à p. 10 - 4

– lubricate the pins Auxiliary single-sheave boom top

à p. 10 - 4

– lubricate the pins

10.2.2

Maintenance plan M 12

M 12

Maintenance work on the LATTICE EXTENSION: every twelve months/after 1 000 oper. hrs.

Swing-away lattice

à p. 10 - 5

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– Lubricate joints

10 - 2

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Lattice extension operating manual GMK 6300L-1

Maintenance 10.3 Description of maintenance work

10.3

Description of maintenance work

10.3.1

Lubricate the pins

Grease, spare parts and tools

Grease1)

Designation as per DIN 51502

Specification Classification

GROVE part no.1)

KP - L2K

DIN 51825

00554201

Grease 1)

M1

à Maintenance manual, Lubricant list and lubricant use

– Brush.

Designation

Quantity

GROVE part no.

No spare parts

H On the swingaway lattice

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

Prerequisites – The truck crane must be secured to prevent unauthorised use; tenance manual, or: – swing-away lattice is removed;

à Main-

à p. 4 - 10.

Lubricating the pins: Lubricate all pins: – Pins for the connections with folded swing-away lattice;

à p. 4 - 38,

– The pins for the connections on the left and right of the main boom head; p. 4 - 54,

à

– Pins for the section 1 and section 2 connections; – The pins on the deflection sheave,

à p. 4 - 65,

à p. 4 - 71.

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10 - 3

Maintenance 10.3 Description of maintenance work

On the boom extension

Lubricate all pins on the boom extension: – Pins for the section 3 and section 4 connections; – The pins on the deflection sheave;

à p. 5 - 11,

à p. 5 - 20.

On the auxiliary single-sheave boom top

– Lubricate the pins for the connections on the left and right of the main boom head.

10.3.2

Grease the slide faces at the front connection

Grease, spare parts and tools

Grease1) Grease 1)

M1

Designation as per DIN 51502

Specification Classification

GROVE part no.1)

KP - L2K

DIN 51825

00554201

à Maintenance manual, Lubricant list and lubricant use

– Brush.

Designation

Quantity

GROVE part no.

No spare parts

H Prerequisites

Also lubricate the pins after every high-pressure cleaning to ensure their proper function.

– The truck crane must be secured to prevent unauthorised use; Maintenance manual.

à

à p. 4 - 82.

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– The hand-held control unit is connected;

10 - 4

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Lattice extension operating manual GMK 6300L-1

Maintenance 10.3 Description of maintenance work

Grease the slide faces

• Start the engine.

• Grease the slide faces (1).

• Move the swivel ram to the telescoping position and then back to the rigging position.

• Repeat this procedure at least twice to distribute the grease over the slide faces.

10.3.3

M 12

Lubricate joints

Grease, spare parts and tools

Grease1) Grease 1)

Designation as per DIN 51502

Specification Classification

GROVE part no.1)

KP - L2K

DIN 51825

00554201

à Maintenance manual, Lubricant list and lubricant use

– Grease gun.

Designation

Quantity

GROVE part no.

No spare parts

Prerequisites

– The truck crane must be secured to prevent unauthorised use; nance manual, or:

12.03.2018

– swing-away lattice is removed;

à Mainte-

à p. 4 - 10.

s Lattice extension operating manual GMK 6300L-1

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10 - 5

Maintenance 10.3 Description of maintenance work

Lubricate joints In section 1 there is a lubricating nipple (1) – in the pivot point of section 1.

– in the derricking cylinder bearing.

• Clean the grease nipples (1).

• Press grease into the lubrication nipple (1)

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until new grease comes out at the lubricating point.

10 - 6

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Lattice extension operating manual GMK 6300L-1

Index

11

Index The index has the following structure: The names of the parts or components you are searching for are listed in alphabetical order on the far left at the beginning of the line. The following are indented under these terms: – Operations (e.g. positioning/removing the hoist rope) or – Subcategories (e.g. transport) or – Subcategories related to operations (e.g. swivelling the lattice extension).

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

12.03.2018

H

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11 - 1

Index

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Blank page

11 - 2

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Lattice extension operating manual GMK 6300L-1

12.03.2018

Index

A

Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Auxiliary single-sheave boom top Identification and slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13, 3 - 15 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 Rigging In transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 In working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 Positioning/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Possible reeving methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Transport dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13, 3 - 15 Axle loads while driving With 12 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6 With 21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7 With 29 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8 With 37 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9 With the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 With the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10

B

Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 CHECKLIST Rigging the 26/34 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Unrigging the 26/34 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . 5 - 26 Setting the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23 Rigging work Establishing/disconnecting the hydraulic connections . . . . . . . . . . . . . . . . 5 - 14 Folding out/folding in deflection sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20 Installing/removing section 3 and section 4 . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11 Installing/removing the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13 Positioning/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Possible reevings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11 Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10

C

CHECKLIST Installing the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1, 7 - 2

D

Derricking gear Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 90 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 89 Driving with rigged lattice extension

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11 - 3

Index

11 - 4

E

Electrical system On the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 68

F

Finding information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9

H

Heavy load lattice extension Fixing/releasing the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 Installing the heavy load lattice extension checklist . . . . . . . . . . . . . . . . . 7 - 1, 7 - 2 Positioning/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14 Rigging To set the angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13 Installing/removing the chain hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12 Transport positions and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7 Hoist rope Possible reeving methods on the auxiliary single-sheave boom top . . . . . . . . 6 - 4 Possible reeving methods on the swing-away lattice . . . . . . . . . . . . . . . . . . . 4 - 73 Possible reevings on the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Hose drum Locking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 47 Positions of the connections Main boom operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 46 Working with the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 45 Hydraulic system On the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14 On the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 48

I

Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Installing/removing the air traffic control light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 79 Installing/removing the anemometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 79 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

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Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 3 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 3 Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2 Rigging mode and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1 Table with axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5

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Index

L

Lattice extension CHECKLIST Auxiliary single-sheave boom top in the working position/transport position 6 -3 Installing the 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8 Installing/removing auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . 6 - 1 Removing 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10 Rigging 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14, 4 - 19 Rigging the 26/34 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Unrigging 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . 4 - 25, 4 - 29 Unrigging the 26/34 m boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Rigging work Making/breaking the slewing connection . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 57 Undoing the slewing connection - For crane operation with main boom 4 - 58 Undoing the slewing connection - For on-road driving . . . . . . . . . . . . . . . 4 - 58 Lattice extension operating manual Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Conversion table for US measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10 Definition of direction references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 Finding information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Notes on ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Qualifications of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Safety instructions for working with lattice extensions . . . . . . . . . . . . . . . . . . . 2 - 3 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

M

Maintenance Assemblies endangered by cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1 Maintenance plan M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2 Maintenance plan M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2 Maintenance work Lubricate the pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3 Lubricating joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5 Malfunctions When working with the swing-away swing-away lattice . . . . . . . . . . . . . . . . . 4 - 94

O

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13, 3 - 15 Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 Swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

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P

Positional references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 Possible reeving methods On the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 On the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 73 Possible reevings On the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21

R

Rigging work Derricking cylinder positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44 Derricking the swing-away lattice when rigging . . . . . . . . . . . . . . . . . . . . . . . . 4 - 82

S

Safety instructions For working with lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Short description of the controls In the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 On the hand-held control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 On the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 Swing-away lattice Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 CHECKLIST Installing the 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8 Removing 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10 Rigging 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14, 4 - 19 Unrigging 12/21 m swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . 4 - 25, 4 - 29 Controls In the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 On the hand-held control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 On the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 Finding and eliminating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 94 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4 Maintenance work Assemblies endangered by cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1 Operation Information about the SLI shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 91 Main boom operation when the swing-away lattice is folded/rigged . . . . 4 - 92 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . 4 - 91 Telescoping with rigged heavy load lattice extension . . . . . . . . . . . . . . . . 4 - 88 Overview of the required rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 Rigging work Check whether the swing-away lattice is secured for transport . . . . . . . . 4 - 36 Connections, folded swing-away lattice In the middle area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 49 Derricking the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 82 Derricking the swing-away lattice when rigging . . . . . . . . . . . . . . . . . . . . . 4 - 82 Folding deflection sheave in/out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 71 Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 76 Making/breaking connections to the swing-away lattice . . . . . . . . . . . . . . 4 - 65

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Index

Making/breaking the electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 68 Making/breaking the hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 48 Positioning/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 73 Securing the swing-away lattice with a rope . . . . . . . . . . . . . . . . . . . . . . . . 4 - 35 Swinging the lattice extension when rigging When rigging section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 61 When rigging section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 62 When unrigging section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 62 When unrigging section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 64 Short description of the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7 Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 Swivel ram Rigging/telescoping position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 40 Swivel ram rigging position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 40 Swivel ram telescoping position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 40 Symbols Used ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Transport Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13, 3 - 15 Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 Swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 To check whether the swing-away lattice is secured for transport . . . . . . . . . 4 - 36

W

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

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