GROVE Crane GMK 4080-2 Lattice Extension Operating Instruction Manual 3302915 – PDF DOWNLOAD

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GROVE Crane GMK 4080-2 Lattice Extension Operating Instruction Manual 3302915 – PDF DOWNLOAD

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GROVE Crane GMK 4080-2 Lattice Extension Operating Instruction Manual 3302915 – PDF DOWNLOAD

Language : English
Pages : 382
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

GROVE Crane GMK 4080-2 Lattice Extension Operating Instruction Manual 3302915 – PDF DOWNLOAD

Basic safety instructions:

• In principle, all the basic safety instructions from the Operating instructions GMK4080-2 are
  applicable.
• Observe also all safety instructions and warnings on the truck crane!
  Information regarding the warnings and symbols used; à Operating instructions GMK4080-2.

Other applicable documents:

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

Safety instructions for working with a lattice extension:

This chapter only contains additional safety instructions for safe use of the lattice extensions
described in these operating instructions.
Working at heights:

• If there is a risk of falling when doing work on the truck crane, suitable equipment must be used
  to prevent falling (e. g. ladder, lifting platform, auxiliary crane).
• The lattice extensions are provided with brackets for positioning a ladder. Place the ladder
  between the brackets so it cannot slip off.
• If despite using such equipment the risk of falling cannot be minimised, you must protect yourself
  and any assisting personnel by using approved fall prevention safety systems.
• The points at which the fall prevention safety system can be attached to on
  the truck crane are indicated by the symbol shown here.

TABLE OF CONTENTS:

GROVE Crane GMK 4080-2 Lattice Extension Operating Instruction Manual 3302915 – PDF DOWNLOAD

1 About these operating instructions................................................................................ 29
	1.1 Validity.................................................................................................... 29
		Validity of these operating instructions.................................................................... 29
		Prerequisites for assembly and operation.................................................................... 29
		References to other operating manuals....................................................................... 29
	1.2 Terms used.................................................................................................. 31
2 Basic safety instructions......................................................................................... 33
	2.1 Other applicable documents.................................................................................. 33
	2.2 Safety instructions for working with a lattice extension.................................................... 34
		Working at heights.......................................................................................... 34
		Slinging.................................................................................................... 34
		Locks....................................................................................................... 34
		Rigging mode................................................................................................ 34
		Two cranes.................................................................................................. 34
3 Operating elements................................................................................................ 35
	3.1 On the lattice extension.................................................................................... 36
		3.1.1 Overview.............................................................................................. 36
		3.1.2 Connection section 1/main boom, rear.................................................................. 37
		3.1.3 Connection section 2/main boom, rear.................................................................. 37
		3.1.4 Connection section 1/main boom, front................................................................. 38
		3.1.5 Connection section 1/section 2, front................................................................. 38
		3.1.6 Connection section 2/main boom, front................................................................. 39
		3.1.7 Connection section 1/section 2, rear.................................................................. 39
		3.1.8 Section 2 control unit................................................................................ 40
	3.2 In the crane cab............................................................................................ 41
		3.2.1 Overview.............................................................................................. 41
		3.2.2 On the CCS control unit............................................................................... 42
		3.2.3 On the CCS control unit............................................................................... 43
			Enter rigging mode/telescope status menu................................................................ 43
		3.2.4 At the right-hand control console..................................................................... 44
	3.3 On the hand-held control.................................................................................... 45
		3.3.1 Connecting hand-held control.......................................................................... 46
			Connecting the hand-held control........................................................................ 46
	3.4 Other operating elements.................................................................................... 47
		3.4.1 Rigging hook.......................................................................................... 47
4 Rigging work on the main boom..................................................................................... 49
	4.1 Hose drum................................................................................................... 49
		4.1.1 Slinging points....................................................................................... 49
		4.1.2 Transport dimensions and weights...................................................................... 50
	4.2 Rigging work on the hose drum............................................................................... 51
		4.2.1 Fitting/removing the hose drum........................................................................ 51
			Installing.............................................................................................. 51
			Removing................................................................................................ 52
		4.2.2 Checking the locking device on the hose drum.......................................................... 53
		4.2.3 Positions of the hydraulic connections during operation............................................... 54
			Working with the lattice extension...................................................................... 54
			Main boom operation..................................................................................... 55
		4.2.4 Positions of the hydraulic hoses when rigging......................................................... 56
			When unrigging.......................................................................................... 56
			When rigging............................................................................................ 57
5 Swing-away lattice................................................................................................ 59
	5.1 Notes on this chapter....................................................................................... 59
	5.2 Operations planning......................................................................................... 60
		5.2.1 Assembly.............................................................................................. 60
		5.2.2 Identification........................................................................................ 61
		5.2.3 Slinging points....................................................................................... 62
			On section 1............................................................................................ 62
			Section 2 and combinations.............................................................................. 62
		5.2.4 Transport dimensions and weights...................................................................... 65
		5.2.5 Transport condition – removed......................................................................... 66
			On the swing- away lattice.............................................................................. 67
			On the main boom........................................................................................ 68
		5.2.6 Transport condition – folded.......................................................................... 69
			Section 1 only.......................................................................................... 69
			Section 2 only.......................................................................................... 70
			Section 1 and section 2................................................................................. 71
	5.3 Checklists for rigging work................................................................................. 73
		5.3.1 Overview.............................................................................................. 73
		5.3.2 CHECKLIST: Installing the swing-away lattice – in operating position.................................. 75
		5.3.3 CHECKLIST: Installing the swing-away lattice – in transport position.................................. 79
		5.3.4 CHECKLIST: Removing the swing-away lattice – from operating position.................................. 83
		5.3.5 CHECKLIST: Removing the swing-away lattice – from transport position.................................. 89
		5.3.6 CHECKLIST: Rigging the swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft) – in the operating position..... 93
		5.3.7 CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – in the operating position.... 97
		5.3.8 CHECKLIST: Rigging the swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft) – in the transport position.....103
		5.3.9 CHECKLIST: Rigging the swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft) – in the transport position....109
		5.3.10 CHECKLIST: Further rigging work......................................................................115
	5.4 Rigging work................................................................................................117
		5.4.1 Notes on the position of the telescoping cylinder.....................................................117
		5.4.2 Secure the swing-away lattice with guide rope.........................................................118
		5.4.3 Establish/disconnect the connection section 2–main boom, front........................................119
			Connecting..............................................................................................119
			Disconnecting...........................................................................................119
		5.4.4 Section 1/main boom, front – establish/disconnect the connection......................................121
			Connecting..............................................................................................121
			Disconnecting...........................................................................................121
		5.4.5 Section 1/section 2, front – establish/disconnect the connection......................................122
			Connecting..............................................................................................122
			Disconnecting...........................................................................................122
		5.4.6 Section 2/main boom, rear – establish/disconnect the connection.......................................123
			Connecting..............................................................................................123
			Disconnecting...........................................................................................123
		5.4.7 Section 1/main boom, rear – establish/disconnect the connection.......................................124
			Connecting..............................................................................................124
			Disconnecting...........................................................................................124
		5.4.8 Establishing/disconnecting the slewing connection.....................................................125
			Disconnecting...........................................................................................126
		5.4.9 Establishing/disconnecting the connection between the main boom/section 2.............................127
		5.4.10 Relieving the strain on the connecting points........................................................128
			For derricking swing-away lattice.......................................................................128
			For a derricking swing-away lattice without hydraulic rigging aid.......................................128
			For a derricking swing-away lattice with hydraulic rigging aid..........................................129
		5.4.11 Section 1/section 2 – Establish/disconnect the left-hand connection..................................131
		5.4.12 Section 1/section 2 – Establish/disconnect the right-hand connection.................................133
		5.4.13 Swinging the swing-away lattice......................................................................135
		5.4.14 Swinging section 1...................................................................................137
		5.4.15 Establishing/disconnecting the hydraulic connection – when rigging...................................138
			Connecting..............................................................................................138
			Disconnecting...........................................................................................139
		5.4.16 Establishing/disconnecting the hydraulic connection – when installing................................140
			Connecting..............................................................................................140
			Disconnecting...........................................................................................141
		5.4.17 Establishing/disconnecting electrical connections....................................................142
			Section 2 – Main boom...................................................................................143
			Section 1 – section 2...................................................................................145
		5.4.18 Fold the deflection sheave in/out on section 2.......................................................147
			Folding out.............................................................................................147
			Folding in..............................................................................................148
		5.4.19 Attaching/removing the hoist rope....................................................................149
			Fitting.................................................................................................149
			Removing................................................................................................150
			Reeving options.........................................................................................151
		5.4.20 Installing/removing the lifting limit switch.........................................................152
			Installing..............................................................................................152
			Removing................................................................................................153
		5.4.21 Installing/removing the anemometer and air traffic control light.....................................154
			Installing..............................................................................................154
			Removing................................................................................................155
		5.4.22 Derricking the swing-away lattice for rigging work – hand-held control...............................156
		5.4.23 Installing/removing the camera.......................................................................157
			Installing..............................................................................................157
			Removing................................................................................................158
		5.4.24 Derricking the swing-away lattice – Section 2 control unit...........................................159
		5.4.25 Setting the angle – with an auxiliary crane..........................................................160
		5.4.26 Setting the angle – without an auxiliary crane.......................................................161
			Enter the RCL code......................................................................................161
			Setting the angle.......................................................................................162
			Setting a 0° angle......................................................................................164
			Inclining the truck crane...............................................................................166
	5.5 Operation with swing-away lattice...........................................................................167
		5.5.1 Setting the RCL.......................................................................................167
			Input...................................................................................................167
			Shutdown................................................................................................168
		5.5.2 Derricking the main boom..............................................................................168
			Slewing range of 360°...................................................................................168
		5.5.3 Telescoping with rigged swing-away lattice............................................................169
			Slewing range of 360°...................................................................................169
		5.5.4 Derricking the swing-away lattice in operation........................................................169
			Switching on the derricking gear........................................................................169
			Raising and lowering....................................................................................170
			Switching off the derricking gear.......................................................................170
		5.5.5 Procedure if permissible wind speed is exceeded.......................................................171
		5.5.6 Information about the main boom operation when the swing-away lattice is folded/rigged................172
			Folded..................................................................................................172
			Rigged..................................................................................................172
		5.5.7 Instructions for turning loads over...................................................................173
	5.6 Maintenance.................................................................................................175
		5.6.1 Maintenance plan W....................................................................................175
		5.6.2 Maintenance plan M 1..................................................................................175
		5.6.3 Maintenance plan M 3..................................................................................175
		5.6.4 Maintenance plan M 12.................................................................................176
		5.6.5 Description of maintenance work.......................................................................176
			Pins....................................................................................................176
			Sheaves.................................................................................................178
			Piston rod..............................................................................................179
			Joints..................................................................................................180
	5.7 Finding and eliminating malfunctions........................................................................181
		5.7.1 Troubleshooting table.................................................................................181
6 Boom extension....................................................................................................183
	6.1 Notes on this chapter.......................................................................................183
	6.2 Operations planning.........................................................................................185
		6.2.1 Assembly..............................................................................................185
		6.2.2 Identification........................................................................................186
			Section 3...............................................................................................186
		6.2.3 Slinging points.......................................................................................187
			Section 3...............................................................................................187
		6.2.4 Transport dimensions and weights......................................................................188
		6.2.5 Transport condition...................................................................................188
			Section 3...............................................................................................188
	6.3 Checklists for rigging work.................................................................................189
		6.3.1 Overview..............................................................................................189
		6.3.2 CHECKLIST: Installing the boom extension..............................................................190
		6.3.3 CHECKLIST: Removing the boom extension................................................................195
	6.4 Description of the rigging work.............................................................................201
		6.4.1 Section 3 – Folding out/folding in the deflection sheave..............................................201
		6.4.2 Section 3/main boom – Establish/disconnect the connection.............................................202
		6.4.3 Section 3/main boom – Establish/disconnect the electrical connections.................................204
		6.4.4 Section 3/main boom – Establish/disconnect the hydraulic connection...................................206
		6.4.5 Section 3/swing-away lattice – Establish/disconnect the connection....................................207
		6.4.6 Section 3/swing-away lattice – Establish/disconnect the electrical connections........................209
		6.4.7 Section 3/swing-away lattice – Establish/disconnect the hydraulic connection..........................211
		6.4.8 Section 3 – Fitting/removing the hoist rope...........................................................212
	6.5 Operation with boom extension...............................................................................213
		6.5.1 Setting the RCL.......................................................................................213
			Input...................................................................................................213
			Shutdown................................................................................................214
		6.5.2 Derricking, telescoping the main boom.................................................................214
			Slewing range of 360°...................................................................................214
		6.5.3 Procedure if permissible wind speeds are exceeded.....................................................215
		6.5.4 Instructions for turning loads over...................................................................215
	6.6 Maintenance.................................................................................................217
		6.6.1 Maintenance plan M 1..................................................................................217
		6.6.2 Maintenance plan M 3..................................................................................217
		6.6.3 Description of maintenance work.......................................................................218
7 Heavy load lattice extension, 2.0 m (6.6 ft)......................................................................219
	7.1 Operations planning.........................................................................................219
		7.1.1 Assembly..............................................................................................219
		7.1.2 Identification........................................................................................220
		7.1.3 Slinging points.......................................................................................221
		7.1.4 Transport dimensions and weights......................................................................222
		7.1.5 Transport condition...................................................................................223
	7.2 Checklists for rigging work.................................................................................225
		7.2.1 Overview..............................................................................................225
		7.2.2 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) installation into the working position.........226
		7.2.3 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) Installation into the transport position.......229
		7.2.4 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) removal from the working position..............231
		7.2.5 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) removal from the transport position............234
		7.2.6 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) rigging into the working position..............236
		7.2.7 CHECKLIST: Heavy load lattice extension 2.0 m (6.6 ft) rigging into the transport position............239
	7.3 Description of the rigging work.............................................................................243
		7.3.1 Section 5/main boom– Establish/separate the connection in the working position........................243
		7.3.2 Section 5/main boom – Establish/separate the connection in the transport position.....................244
		7.3.3 Bringing section 5 from the transport position into the working position..............................246
		7.3.4 Bringing section 5 from the working position into the transport position..............................248
		7.3.5 Folding the rope attachment point in/out..............................................................250
		7.3.6 Section 5 – Setting the angle – with the hoist rope...................................................251
		7.3.7 Section 5 – Setting the angle – with a chain hoist....................................................253
		7.3.8 Section 5 –Fitting/removing the hoist rope............................................................255
		7.3.9 Possible reeving methods on the heavy load lattice extension..........................................256
		7.3.10 Installing/removing the lifting limit switch.........................................................257
			Installation............................................................................................257
			Removing................................................................................................258
		7.3.11 Installing / removing the anemometer and air traffic control light...................................259
			Installing and removing.................................................................................259
		7.3.12 Installing/removing the camera.......................................................................260
			Installation............................................................................................260
			Removing................................................................................................261
	7.4 Operating the heavy load lattice extension..................................................................263
		7.4.1 Setting the RCL.......................................................................................263
			Input...................................................................................................263
			shutdown................................................................................................264
		7.4.2 Derricking, telescoping the main boom.................................................................265
			Slewing range of 360°...................................................................................265
		7.4.3 Procedure if permissible wind speeds are exceeded.....................................................266
		7.4.4 Instructions for turning loads over...................................................................266
	7.5 Maintenance.................................................................................................267
		7.5.1 Maintenance plan M 1..................................................................................267
		7.5.2 Maintenance plan M 3..................................................................................267
		7.5.3 Description of maintenance work.......................................................................268
8 Heavy load lattice extension 1.8 m (5.9 ft).......................................................................269
	8.1 Operations planning.........................................................................................269
		8.1.1 Possible operating modes..............................................................................269
		8.1.2 Assembly..............................................................................................270
		8.1.3 Identification........................................................................................270
		8.1.4 Slinging points.......................................................................................271
			Heavy load lattice extension............................................................................271
			Sheaves package.........................................................................................272
			Shackle.................................................................................................272
		8.1.5 Transport dimensions and weights......................................................................273
			Heavy load lattice extension............................................................................273
			Shackle.................................................................................................273
			Sheaves package.........................................................................................273
		8.1.6 Transport condition...................................................................................274
	8.2 Checklists for rigging work.................................................................................277
		8.2.1 Overview..............................................................................................277
		8.2.2 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) installation into the working position.........278
		8.2.3 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) installation into the transport position.......281
		8.2.4 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) removal from the working position..............283
		8.2.5 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) removal from the transport position............286
		8.2.6 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) rigging into the working position..............288
		8.2.7 CHECKLIST: Heavy load lattice extension 1.8 m (5.9 ft) rigging into the transport position............291
	8.3 Rigging work................................................................................................295
		8.3.1 Section 6/main boom – Establish/separate the connection in the working position.......................295
		8.3.2 Section 6/main boom– Establish/separate the connection in the transport position......................296
		8.3.3 Bringing section 6 from the transport position into the working position..............................298
		8.3.4 Bringing section 6 from the working position into the transport position..............................300
		8.3.5 Folding the rope attachment point in/out..............................................................303
		8.3.6 Section 6 – Setting the angle - with the hoist rope...................................................304
		8.3.7 Section 6 – Setting the angle - with a chain hoist....................................................306
		8.3.8 Section 6 – Fitting/removing the hoist rope...........................................................308
		8.3.9 Possible reeving methods on the heavy load lattice extension..........................................309
		8.3.10 Installing/removing the lifting limit switch.........................................................311
			Installation............................................................................................311
			Removing................................................................................................312
		8.3.11 Installing / removing the anemometer and air traffic control light...................................313
		8.3.12 Installing/removing the camera.......................................................................314
			Installation............................................................................................314
			Removing................................................................................................315
		8.3.13 Installing/removing the air traffic control light....................................................316
			Installing..............................................................................................316
			Removing................................................................................................317
		8.3.14 Installing/removing the shackle......................................................................318
			Installing..............................................................................................318
			Removing................................................................................................319
		8.3.15 Folding in/folding out the shackle...................................................................320
	8.4 Heavy load lattice extension – Operation with hoist rope....................................................321
		8.4.1 Setting the RCL.......................................................................................321
			Input...................................................................................................321
			Shutdown................................................................................................322
		8.4.2 Derricking, telescoping the main boom.................................................................323
			Slewing range of 360°...................................................................................323
		8.4.3 Procedure if permissible wind speeds are exceeded.....................................................324
		8.4.4 Instructions for turning loads over...................................................................324
	8.5 Heavy load lattice extension – Operation with a shackle.....................................................325
		8.5.1 Setting the RCL.......................................................................................325
			Input...................................................................................................325
			Shutdown................................................................................................326
		8.5.2 Derricking the main boom..............................................................................327
			Lifting the load........................................................................................327
			Derricking..............................................................................................328
		8.5.3 Telescoping the main boom.............................................................................329
		8.5.4 Procedure if permissible wind speeds are exceeded.....................................................330
	8.6 Maintenance.................................................................................................331
		8.6.1 Maintenance plan M 1..................................................................................331
		8.6.2 Maintenance plan M 3..................................................................................331
		8.6.3 Maintenance plan M 12.................................................................................331
		8.6.4 Description of maintenance work.......................................................................332
9 Auxiliary single-sheave boom top..................................................................................333
	9.1 Operations planning.........................................................................................333
		9.1.1 Identification and slinging points....................................................................333
		9.1.2 Transport dimensions and weights......................................................................334
		9.1.3 Transport condition...................................................................................334
	9.2 Description of the rigging work.............................................................................337
		9.2.1 Moving the auxiliary single-sheave boom top into operating position...................................337
		9.2.2 Moving the auxiliary single-sheave boom top into the transport position...............................339
		9.2.3 Installing/removing a folded auxiliary single-sheave boom top.........................................341
		9.2.4 Attaching/removing the hoist rope.....................................................................343
		9.2.5 Installing/removing the lifting limit switch..........................................................344
			Installing..............................................................................................344
			Removing................................................................................................345
		9.2.6 Installing/removing the anemometer and air traffic control light......................................346
			Installing and removing.................................................................................346
		9.2.7 Installing/removing the camera........................................................................346
	9.3 Operation with the auxiliary single-sheave boom top.........................................................347
		9.3.1 Setting the RCL.......................................................................................347
			Input...................................................................................................347
			Shutdown................................................................................................348
		9.3.2 Procedure if permissible wind speeds are exceeded.....................................................349
		9.3.3 Instructions for turning loads over...................................................................349
	9.4 Maintenance.................................................................................................351
		9.4.1 Maintenance plan M 1..................................................................................351
		9.4.2 Maintenance plan M 3..................................................................................351
		9.4.3 Description of maintenance work.......................................................................352
10 Turning loads over...............................................................................................353
	Prerequisites...................................................................................................353
	10.1 Setting the RCL............................................................................................354
		Entering the reeving........................................................................................354
		Switching over to the auxiliary hoist.......................................................................354
	10.2 Turning a load over........................................................................................355
11 Driving with a rigged crane......................................................................................357
	11.1 Safety instructions........................................................................................357
	11.2 Driving path...............................................................................................358
	11.3 Permissible rigging modes and axle loads...................................................................359
		Notes on the tables.........................................................................................359
		11.3.1 Swing-away lattice...................................................................................360
			Swing-away lattice 1.2 + 7.5 m (3.9 + 24.6 ft)..........................................................360
			Swing-away lattice 1.2 + 13.8 m (3.9 + 45.3 ft).........................................................362
		11.3.2 Boom extension.......................................................................................364
			Boom extension 7.7 + 13.8 m (23.6 + 45.3 ft)............................................................364
		11.3.3 Heavy load lattice extension 2.0 m (6.6 ft)..........................................................366
			Heavy load lattice extension 2.0 m (6.6 ft).............................................................366
		11.3.4 Heavy load lattice extension 1.8 m (5.9 ft)..........................................................368
			Heavy load lattice extension 1.8 m (5.9 ft).............................................................368
		11.3.5 Auxiliary single-sheave boom top.....................................................................370
	11.4 Before driving.............................................................................................371
	11.5 While driving..............................................................................................371
	11.6 After driving..............................................................................................371
12 Index............................................................................................................373
	A...............................................................................................................375
	B...............................................................................................................375
	D...............................................................................................................376
	H...............................................................................................................376
	L...............................................................................................................378
	M...............................................................................................................378
	O...............................................................................................................378
	P...............................................................................................................379
	R...............................................................................................................379
	S...............................................................................................................379
	T...............................................................................................................380

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