Grove Crane GMK 4080-1 Lattice Extension Operating Instruction Manual 3302391 – PDF DOWNLOAD

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Grove Crane GMK 4080-1 Lattice Extension Operating Instruction Manual 3302391 – PDF DOWNLOAD

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Grove Crane GMK 4080-1 Lattice Extension Operating Instruction Manual 3302391 – PDF DOWNLOAD

Language : English
Pages : 264
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Grove Crane GMK 4080-1 Lattice Extension Operating Instruction Manual 3302391 – PDF DOWNLOAD

Intended use:
The truck crane GMK 4080-1 is constructed in accordance with the latest technology and the
recognized safety regulations. Nevertheless, personal injury to the operator or a third party as
well as damage to the crane and other property may occur during use.

• The truck crane may only be modified with the consent of the manufacturer.
• The truck crane GMK 4080-1 may only be used when in excellent working condition and for its
  intended purpose, and with due attention to safe operation and any possible hazards.
  Malfunctions that may affect the safe operation of the unit are to be corrected immediately.
• The GMK 4080-1 truck crane may only be operated at temperatures of between –25 and +40 °C if it is
  not equipped with the relevant special equipment.
• The GMK 4080-1 truck crane may only be used for the vertical lifting of loads, in the authorized
  rigging modes and using a hook block that is reeved to the hoist rope. The weight and centre of
  distribution of the loads must be known. Any other use of the crane is not considered to represent
  intended use.
• The manufacturer is not liable for damage resulting from the improper or unauthorized use of the
  GMK 4080-1 truck crane. The user shall take full responsibility for any such use.

Intended use also entails

– observing the complete crane documentation consisting of the operating instructions, the lifting
capacity table, the outrigger pressure table and the safety manual
– adhering to the inspection and maintenance requirements specified in the maintenance manual.

Improper use includes:

– Transporting loads on the carrier
– Pushing, pulling or lifting loads with the level adjustment system, the beams or the outrigger
cylinders
– Pushing, pulling or lifting loads off the ground using the slewing gear, the derricking gear or
the telescoping mechanism
– Pulling off fixed objects using the crane
– Two-hook operation with the boom extension and two-hook operation on the main boom head without
additional equipment
– Defining RCL codes that do not correspond to the actual rigging mode
– Working with an overridden RCL or overridden lifting limit switch
– After RCL deactivation, increasing the radius by pulling the raised load at an angle (e.g. with
a chain hoist)
– Misuse of the outrigger pressure indicator as a safety function to prevent overturning after an
RCL shutdown (outrigger pressure greater than 0 t)
– Road driving in an unauthorized driving mode (axle load, dimension)
– Moving the rigged crane in an unauthorized driving mode
– Use of equipment that is not authorized for use with the crane
– Transporting people in any way with the lifting tackle, upon the load, or in the crane cab while
driving
– Carrying passengers outside the driver’s cab
– Loading and unloading work, i.e. continuous operation without a suffi- ciently long break
– Usage for any kind of sport or recreation event, especially for bungee
jumping

TABLE OF CONTENTS:

Grove Crane GMK 4080-1 Lattice Extension Operating Instruction Manual 3302391 – PDF DOWNLOAD

1 Important information.........................................................................................  7
	1.1 About these operating instructions......................................................................  7
		Validity of these operating instructions................................................................  7
		Prerequisites for assembly and operation................................................................  7
		Safety instructions....................................................................................  7
		References to other operating instructions..............................................................  7
	1.2 Basic safety instructions...............................................................................  8
		1.2.1 Warnings and symbols..............................................................................  8
	1.3 Intended use............................................................................................  9
	1.4 Organizational measures................................................................................. 11
	1.5 Personnel qualifications................................................................................ 13
	1.6 Safety instructions for truck crane work................................................................ 14
	1.7 Specifications in US standard units of measurement...................................................... 16
2 Transport dimensions and weights.............................................................................. 19
	2.1 Swing-away lattice extension............................................................................ 19
	2.2 Boom extension.......................................................................................... 19
	2.3 Auxiliary single-sheave boom top........................................................................ 19
	2.4 Heavy load lattice extension............................................................................ 20
3 8.7/15 m (28.5/49 ft) swing-away lattice extension............................................................ 23
	3.1 Validity................................................................................................ 23
	3.2 Additional operating and display elements............................................................... 23
		3.2.1 In the crane cab.................................................................................. 24
			At the control console right........................................................................ 24
			On the crane control display........................................................................ 25
			On the safe load indicator.......................................................................... 26
		3.2.2 Operating and display elements on the hand-held control........................................... 27
		3.2.3 Operating and display instruments on the swing-away lattice extension............................. 28
	3.3 Identification of the swing-away lattice extension...................................................... 29
		Serial number on section1.............................................................................. 30
		Serial number on section2.............................................................................. 30
	3.4 Composition of the swing-away lattice extension......................................................... 31
	3.5 Centres of gravity for slinging......................................................................... 33
	3.6 Checklists for rigging work............................................................................. 35
		3.6.1 Overview of the required rigging work............................................................. 35
		3.6.2 CHECKLIST: Installing 8.7/15 m (28.5/49 ft) swing-away lattice extension.......................... 36
		3.6.3 CHECKLIST: Removing 8.7/15 m (28.5/49 ft) swing-away lattice extension............................ 38
			For a rigged lattice extension...................................................................... 38
			For a folded lattice extension...................................................................... 40
		3.6.4 CHECKLIST: Rigging the 8.7/15 m (28.5/49 ft) swing-away lattice extension......................... 42
		3.6.5 CHECKLIST: Unrigging the 8.7/15m (28.5/49ft) swing-away lattice extension....................... 48
	3.7 Description of rigging work............................................................................. 55
		3.7.1 Preparing the truck crane for rigging............................................................. 55
			Prerequisites for rigging........................................................................... 55
			Prerequisites for unrigging......................................................................... 55
			Securing lattice extension with cord................................................................ 56
		3.7.2 Checking the transport condition.................................................................. 57
			Transport condition with removed lattice extension.................................................. 62
		3.7.3 Checking the anti-twist device on the hose drum................................................... 63
		3.7.4 Establishing/disconnecting the hydraulic connection............................................... 65
			Establishing the hydraulic connection............................................................... 65
			Breaking the hydraulic connection................................................................... 66
		3.7.5 Guides and holders for the hydraulic hoses........................................................ 67
			When unrigging...................................................................................... 67
			When rigging........................................................................................ 68
		3.7.6 Connections with folded lattice extension......................................................... 69
			Connections in the Front 1 area..................................................................... 69
			Connections in the Front 2 area..................................................................... 71
			Connections in the middle area...................................................................... 73
			Connections in the rear area........................................................................ 75
		3.7.7 Securing/releasing section 2..................................................................... 77
		3.7.8 Connecting/disconnecting the slewing connection................................................... 79
			Creating a slewing connection....................................................................... 79
			Releasing a slewing connection...................................................................... 80
		3.7.9 Connections on the left and right of the main boom head........................................... 81
			Establishing connections............................................................................ 81
			Releasing connections.............................................................................. 82
			Relieving the connecting points..................................................................... 84
		3.7.10 Swivelling the lattice extension when rigging.................................................... 87
			When rigging – section1............................................................................ 87
			When unrigging – section1.......................................................................... 88
			When rigging – section2............................................................................ 89
			When unrigging – section2.......................................................................... 90
		3.7.11 Establishing/releasing connections on the lattice extension..................................... 92
			Section1 and section2 installed................................................................... 93
			Only section1 installed........................................................................... 94
		3.7.12 Electrical connections on the lattice extension.................................................. 95
			On 8.7 m (28.5 ft) swing-away lattice extension..................................................... 95
			On 15 m (49 ft)- swing-away lattice extension....................................................... 97
		3.7.13 Unfolding/folding the deflection sheave.......................................................... 98
			Folding out the deflection sheave.................................................................. 98
			Folding in the deflection sheave................................................................... 99
		3.7.14 Positioning/removing the hoist rope..............................................................100
			Positioning hoist rope.............................................................................100
			Removing the hoist rope............................................................................100
			Possible reeving methods on the lattice extension..................................................101
		3.7.15 Installing/removing the lifting limit switch.....................................................102
			Overriding connection on main boom..................................................................102
			On 8.7 m (28.5 ft) swing-away lattice extension.....................................................103
			On 15 m (49 ft) swing-away lattice extension........................................................104
		3.7.16 Installing/removing the anemometer...............................................................105
			On 8.7 m (28.5 ft) swing-away lattice extension.....................................................105
			On 15 m (49 ft) swing-away lattice extension........................................................106
		3.7.17 Air traffic control light – electrical connection................................................107
			Establishing the electrical connection..............................................................107
			Disconnecting the electrical connection.............................................................108
		3.7.18 Derricking the lattice extension.................................................................109
			When rigging........................................................................................109
			During operation....................................................................................111
		3.7.19 Setting the angle – with the auxiliary crane.....................................................112
			Pin positions.......................................................................................113
		3.7.20 Setting the angle – without the auxiliary crane.................................................114
			Entering the RCL code..............................................................................114
			Setting an angle of 20 or 40......................................................................115
			Setting 0 angle....................................................................................117
			Inclining the truck crane...........................................................................119
		3.7.21 Transportation on a separate vehicle.............................................................120
	3.8 Operation with the lattice extension....................................................................121
		3.8.1 Setting the RCL...................................................................................122
			Derrickable lattice extension.......................................................................122
			Inclinable lattice extension........................................................................123
		3.8.2 Raising and setting down the main boom............................................................124
			Raising.............................................................................................124
			Setting down........................................................................................124
		3.8.3 Telescoping with rigged lattice extension.........................................................125
		3.8.4 Information about the RCL shutdown................................................................126
		3.8.5 Procedure if the permissible wind speed is exceeded...............................................127
		3.8.6 Information about the main boom operation when the lattice extension is folded/rigged.............128
			Folded..............................................................................................128
			Rigged..............................................................................................128
	3.9 Turning loads with the lattice extension................................................................131
		3.9.1 Prerequisites.....................................................................................131
		3.9.2 Setting the RCL...................................................................................132
		3.9.3 Turning a load....................................................................................134
	3.10 Driving with rigged crane with a rigged lattice extension..............................................137
		3.10.1 Driving route....................................................................................138
		3.10.2 Boom positions and axle loads....................................................................139
			Notes on the tables.................................................................................139
			8.7 m (28.5 ft) swing-away lattice extension.......................................................140
			15 m (49 ft) swing-away lattice extension.........................................................141
		3.10.3 Driving the rigged crane.........................................................................142
			Closing the slewing gear brake......................................................................142
			Retracting the outriggers...........................................................................142
			Switching over the suspension locking system........................................................143
			Switching on separate steering......................................................................144
			Driving.............................................................................................145
			Align free on wheels truck crane horizontally.......................................................146
			Supporting the truck crane.........................................................................147
	3.11 Finding and eliminating malfunctions...................................................................149
	3.12 Maintenance work.......................................................................................151
		3.12.1 Modules in need of protection during cleaning work...............................................151
		3.12.2 Maintenance work M 1, monthly....................................................................152
			Pins................................................................................................152
		3.12.3 Maintenance work M 12, every twelve months.......................................................153
			Lubricate joints on section1.......................................................................153
4 Boom extension................................................................................................157
	4.1 Identification and slinging points......................................................................157
		4.1.1 Identification....................................................................................157
		4.1.2 Slinging points...................................................................................158
	4.2 Assembly of boom extensions.............................................................................159
	4.3 Checklists for rigging work.............................................................................161
		4.3.1 CHECKLIST: 21m (69ft) rigging of boom extension.................................................161
		4.3.2 CHECKLIST: 21m (69ft) removing boom extension...................................................165
	4.4 Description of rigging work.............................................................................169
		4.4.1 Installing/removing section3.....................................................................169
			Removing............................................................................................169
		4.4.2 Installing/removing the lattice extension for the boom extension.................................170
			Removing............................................................................................171
		4.4.3 Hydraulic connection at the boom extension........................................................172
			Establishing a connection...........................................................................172
			Disconnecting.......................................................................................173
		4.4.4 Electrical connection at the boom extension.......................................................174
			Establishing a connection...........................................................................174
			Disconnecting.......................................................................................175
		4.4.5 Fold the deflection sheave in/out on section3....................................................176
			Folding out the deflection sheave...................................................................176
			Folding in the deflection sheave....................................................................176
		4.4.6 Fitting/removing the hoist rope...................................................................177
			Positioning the hoist rope..........................................................................177
			Removing the hoist rope.............................................................................177
			Possible reeving methods............................................................................178
	4.5 Working with the boom extension.........................................................................179
	4.6 Driving with rigged crane and rigged boom extension.....................................................181
		4.6.1 Route.............................................................................................182
		4.6.2 Boom positions and axle loads.....................................................................183
			Notes on the tables.................................................................................183
			21 m (69 ft) boom extension.........................................................................184
		4.6.3 Driving the rigged crane..........................................................................185
	4.7 Maintenance work........................................................................................187
		4.7.1 Maintenance work M1, monthly.....................................................................187
5 Auxiliary single-sheave boom top..............................................................................191
	5.1 Identification..........................................................................................191
	5.2 Installing/removing auxiliary single-sheave boom top....................................................193
		5.2.1 Installing the auxiliary single-sheave boom top...................................................193
		5.2.2 Removing the auxiliary single-sheave boom top.....................................................194
	5.3 Rigging the auxiliary single-sheave boom top............................................................195
		5.3.1 Rigging in transport position.....................................................................195
		5.3.2 Rigging in working position.......................................................................196
		5.3.3 Attaching and removing the hoist rope.............................................................197
		5.3.4 Setting the RCL...................................................................................197
		5.3.5 Possible reeving methods on the auxiliary single-sheave boom top..................................198
		5.3.6 Lifting limit switch and anemometer...............................................................199
			For operation.......................................................................................199
			For transport.......................................................................................199
			Anemometer..........................................................................................199
	5.4 Operation with the auxiliary single-sheave boom top.....................................................201
	5.5 Turning loads with the auxiliary single-sheave boom top.................................................203
		5.5.1 Prerequisites.....................................................................................203
		5.5.2 Setting the RCL...................................................................................204
		5.5.3 Turning a load....................................................................................206
	5.6 Driving the rigged crane with a rigged auxiliary single- sheave boom top................................209
6 Heavy load lattice extension..................................................................................213
	6.1 Identification..........................................................................................213
	6.2 Attaching and securing the heavy load lattice extension.................................................215
		6.2.1 Slinging point....................................................................................215
		6.2.2 Folding in/out rope attachment point..............................................................216
			Folding out rope attachment point..................................................................216
			Folding in rope attachment point...................................................................216
		6.2.3 Securing the heavy load lattice extension with guide rope.........................................217
	6.3 Installing / removing the heavy load lattice extension..................................................219
		6.3.1 Installing the heavy load lattice extension.......................................................219
		6.3.2 Removing the heavy load lattice extension.........................................................221
	6.4 Rigging the heavy load lattice extension................................................................223
		6.4.1 Rigging in transport position.....................................................................223
		6.4.2 Rigging in working position.......................................................................226
		6.4.3 Setting the angle position of the heavy load lattice extension....................................229
			Installing/removing the chain hoist.................................................................229
			Prerequisites.......................................................................................230
			Setting 40 angle...................................................................................230
			Setting 0 angle....................................................................................231
		6.4.4 Attaching and removing the hoist rope.............................................................232
			Possible reeving methods on the heavy load lattice extension........................................233
		6.4.5 Lifting limit switch and anemometer...............................................................234
			For operation.......................................................................................234
			For transport.......................................................................................234
			Anemometer..........................................................................................234
		6.4.6 Transportation on a separate vehicle..............................................................235
	6.5 Operation with the heavy load lattice extension.........................................................237
		6.5.1 Setting the RCL...................................................................................238
		6.5.2 Raising and setting down the main boom............................................................239
			Raising.............................................................................................239
			Setting down........................................................................................239
		6.5.3 Telescoping with rigged heavy load lattice extension..............................................240
		6.5.4 Information about the RCL shutdown................................................................241
		6.5.5 Procedure if the permissible wind speed is exceeded...............................................241
		6.5.6 Information about the main boom operation when the heavy load lattice extension is folded/r.......242
			Folded..............................................................................................242
			Rigged..............................................................................................242
	6.6 Turning loads with the heavy load lattice extension.....................................................245
		6.6.1 Prerequisites.....................................................................................245
		6.6.2 Setting the RCL...................................................................................246
		6.6.3 Turning a load....................................................................................248
	6.7 Driving with rigged crane and rigged heavy load lattice extension.......................................251
7 Index.........................................................................................................255
	A...........................................................................................................257
	B...........................................................................................................257
	E...........................................................................................................257
	H...........................................................................................................257
	I...........................................................................................................258
	L...........................................................................................................258
	M...........................................................................................................260
	O...........................................................................................................260
	P...........................................................................................................260
	S...........................................................................................................260
	T...........................................................................................................260

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