Grove GMK7450 Operating Instructions Lattice Extension Manual – PDF DOWNLOAD
DESCRIPTION:
Grove GMK7450 Operating Instructions Lattice Extension Manual – PDF DOWNLOAD
Intended use:
- The truck crane GMK 7450 is constructed in accordance with the latest technology and the recognized safety regulations. Nevertheless, personal injury to the operator or a third party as well as damage to the crane and other property may occur during use.
- The truck crane may only be modified with the consent of the manufacturer.
- The truck crane GMK 7450 may only be used when in excellent working condition and for its intended purpose, and with due attention to safe operation and any possible hazards. Malfunctions that may affect the safe operation of the unit are to be corrected immediately.
- The GMK 7450 truck crane may only be operated at temperatures of between –25 and +40 °C if it is not equipped with the relevant special equipment.
- The GMK 7450 truck crane may only be used to vertically lift loads in the authorized rigging modes using a hook block that is reeved to the hoist rope. The weight and centre of 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 truck crane GMK 7450. 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
– Observing 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 gear
– Pulling off fixed objects using the crane
– Two-hook operation with the boom extension and two-hook operation on
the main boom head without additional equipment
– Operation when crane is not on outriggers (free on wheels)
– Defining SLI codes that do not correspond to the actual rigging mode
– Working with an overridden SLI or overridden lifting limit switch
– After SLI deactivation, increasing the radius by pulling the raised load at
an angle (e.g. with a chain hoist)
– Misuse of the outrigger pressure display as a safety function to prevent
overturning after an SLI shutdown (outrigger pressure greater than 0 t)
– Road driving in an unauthorized driving mode (axle load, dimension)
– Moving the rigged crane in an unauthorized driving mode
– The transportation of raised loads by moving the truck crane
– Use of equipment that is not authorized for use with the crane
TABLE OF CONTENTS:
Grove GMK7450 Operating Instructions Lattice Extension Manual – PDF DOWNLOAD
Operating instructions lattice extension................................................................................ 1 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 Reference 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 Organisational measures......................................................................................... 11 1.5 Personnel qualifications........................................................................................ 13 1.6 Safety instructions for truck crane work........................................................................ 14 1.7 Specifications in US units of measurement....................................................................... 16 1.7.1 Boom extension........................................................................................... 16 1.7.2 Luffing jib.............................................................................................. 17 1.7.3 Heavy load lattice extension.............................................................................. 17 2 Transport measurements, weights and allocation of the lattice extension sections...................................... 21 2.1 Transport dimensions and weights................................................................................ 21 2.1.1 Boom extension............................................................................................ 21 2.1.2 Luffing jib............................................................................................... 22 2.1.3 Heavy load lattice extension.............................................................................. 23 2.2 Assignment of the parts to luffing jibs......................................................................... 25 2.2.1 Parts for the different boom extensions................................................................... 25 2.2.2 Parts for the different luffing jibs...................................................................... 27 2.2.3 Parts for the different heavy load lattice extensions..................................................... 29 3 Boom extension........................................................................................................ 33 3.1 Components and identification................................................................................... 33 Components...................................................................................................... 33 Identification.................................................................................................. 34 Foot section.................................................................................................... 34 Intermediate sections.......................................................................................... 35 Reducing piece.................................................................................................. 35 Head section.................................................................................................... 36 Angle piece..................................................................................................... 36 3.2 Possible combinations........................................................................................... 37 Without angle offset.......................................................................................... 37 With angle offset............................................................................................... 40 3.3 Slinging points................................................................................................. 43 3.4 Checklists for rigging work..................................................................................... 47 3.4.1 CHECKLIST: Installing boom extension...................................................................... 47 3.4.2 CHECKLIST: Removing the boom extension.................................................................... 51 3.5 Description of rigging work..................................................................................... 55 3.5.1 Pulling apart/pushing together intermediate sections...................................................... 55 Folding up/folding out holders.............................................................................. 55 Pulling apart intermediate sections......................................................................... 56 Pushing in boom sections.................................................................................... 57 3.5.2 Truck crane rigging mode during installation of the boom extension....................................... 59 3.5.3 Establishing/disconnecting the connections for the hydraulic lock......................................... 60 Establish connections...................................................................................... 60 Disconnecting connections................................................................................... 60 3.5.4 Secure/release hydraulic lock............................................................................. 61 Execution withlevers....................................................................................... 62 Version with locking bar.................................................................................... 63 • Push the locking bar (1) on the handle (2) down....................................................... 63 • Push the locking bar (1) on the handle (2) up......................................................... 63 3.5.5 Locking the foot section/releasing the lock............................................................... 64 Locking the foot section.................................................................................... 64 • Bring the lever (2) on the changeover valve to horizontal position, for the top pin................... 64 Releasing the lock.......................................................................................... 65 • Bring the lever (2) on the changeover valve to horizontal position, for the top pin................... 65 3.5.6 Handling the pins......................................................................................... 66 3.5.7 Installing/removing the boom extension sections........................................................... 67 Checks before installation/ removal......................................................................... 67 Connecting pins............................................................................................ 67 Installation................................................................................................ 68 Removal..................................................................................................... 69 3.5.8 Blocking the joint on the foot section.................................................................... 71 3.5.9 Removing/installing deflection sheave on the angle piece.................................................. 72 3.5.10 Replacing deflection sheaves on the angle piece.......................................................... 73 • Sling the deflection sheave to the safety roller (1)..................................................... 73 • Release the retaining pins and remove both pins (2) from the lower brackets (4)........................... 73 • Lock the deflection sheave in this position with both pins (2)............................................ 73 3.5.11 Fold deflection sheaves up/down.......................................................................... 74 Folding down the deflection sheave......................................................................... 74 Folding up the deflection sheave........................................................................... 74 Folding support roller on the foot section.................................................................. 75 • Release the retaining pin and remove the pins (1) from the connection points (4)...................... 75 • Release the retaining pin and remove the pin (1) from the bore hole (3)............................... 75 • Fold the support roller (2) upwards................................................................... 75 • Insert the pin (1) into the connecting points (4) and secure it with the retaining pin................ 75 3.5.12 Setting the angle position of the boom extension......................................................... 76 Set angle position of 25................................................................................... 77 Set angle position of 3.................................................................................... 77 3.5.13 Changing the lifting limit switch and anemometer......................................................... 78 Changing the lifting limit switch........................................................................... 78 Changing anemometer........................................................................................ 79 3.5.14 Electric connection to the foot section/main boom........................................................ 80 Establishing a connection................................................................................... 80 Detaching the connection.................................................................................... 81 3.5.15 Electric connection to the head section/foot section..................................................... 81 Connecting cable............................................................................................ 81 Establishing a connection................................................................................... 82 Detaching the connection.................................................................................... 83 3.5.16 Placing and reeving hoist rope........................................................................... 84 Possible reeving methods................................................................................... 86 3.6 Working with the boom extension................................................................................. 89 3.6.1 Telescoping with rigged boom extension.................................................................... 90 3.6.2 Crane movements........................................................................................... 91 3.6.3 SLI Overriding............................................................................................ 91 +........................................................................................................... 91 3.6.4 Influence of the wind during operating with boom extension................................................ 92 3.7 Driving with rigged crane and boom extension................................................................... 95 3.7.1 Driving route............................................................................................. 95 3.7.2 Position of the boom and the axle load.................................................................... 96 12 m (39 ft) boom extension................................................................................. 98 18 m (59ft) boom extension................................................................................. 99 24 m (79ft) boom extension.................................................................................100 30 m (98ft) boom extension.................................................................................101 36 m (118ft) boom extension................................................................................102 42 m (138ft) boom extension................................................................................103 46 m (151ft) boom extension................................................................................104 52 m (170ft) boom extension................................................................................105 58 m (190ft) boom extension................................................................................106 64 m (210ft) boom extension................................................................................107 70 m (230ft) boom extension................................................................................108 46 m (151ft) boom extension................................................................................109 52 m (170ft) boom extension................................................................................110 58 m (190ft) boom extension................................................................................111 64 m (210ft) boom extension................................................................................112 70 m (230ft) boom extension................................................................................113 3.7.3 Driving the rigged crane..................................................................................114 Checking the superstructure lock............................................................................114 4.......................................................................................................114 Retracting the outrigger...................................................................................114 Switching over the suspension locking system................................................................114 Driving.....................................................................................................115 Supporting the truck crane.................................................................................116 If necessary, rig the counterweight sections................................................................116 3.8 Boom extension maintenance......................................................................................117 3.8.1 Maintenance plans.........................................................................................117 M 1 maintenance plan:.......................................................................................117 3.8.2 Lubricant table...........................................................................................118 3.8.3 Maintenance work..........................................................................................118 Notes on cleaning work......................................................................................118 Lubricating connecting pins.................................................................................118 4 Luffing jib...........................................................................................................121 4.1 Additional operating and display elements in the cranecab.....................................................121 4.1.1 Additional symbol in main menu............................................................................121 4.1.2 Luffing jib submenu.......................................................................................122 4.1.3 Function of the operating and display elements in the luffing jib submenu.................................124 %...........................................................................................................124 &...........................................................................................................124 (...........................................................................................................125 !...........................................................................................................126 $...........................................................................................................126 "...........................................................................................................126 #...........................................................................................................127 *...........................................................................................................129 ,...........................................................................................................129 -...........................................................................................................130 4.2 Components and identification...................................................................................131 Components......................................................................................................131 Identification..................................................................................................132 Foot section....................................................................................................132 Long intermediate sections......................................................................................133 Reducing piece..................................................................................................133 Head section....................................................................................................134 Luffing control arm.............................................................................................134 Angle piece.....................................................................................................135 4.3 Possible combinations...........................................................................................137 Without angle offset...........................................................................................137 With angle offset...............................................................................................139 4.4 Slinging points.................................................................................................141 4.5 Checklists for rigging work.....................................................................................145 4.5.1 CHECKLIST: Rigging luffing jib............................................................................145 (...........................................................................................................148 &...........................................................................................................151 %...........................................................................................................151 4.5.2 CHECKLIST: Luffing jib removal............................................................................152 %...........................................................................................................152 &...........................................................................................................152 (...........................................................................................................153 4.6 Description of rigging work.....................................................................................159 4.6.1 Pulling apart/pushing together intermediate sections......................................................159 Folding up/folding out holders..............................................................................159 Pulling apart intermediate sections.........................................................................160 Pushing in boom sections....................................................................................161 4.6.2 Rigging mode of the truck crane when mounting the luffing jib............................................163 4.6.3 Installing/disassembling luffing control arm..............................................................164 Installation................................................................................................164 Disassembly.................................................................................................167 4.6.4 Establishing/disconnecting the connections for the hydraulic lock.........................................170 Establish connections......................................................................................170 Disconnecting connections...................................................................................170 4.6.5 Secure/release hydraulic lock.............................................................................171 Execution withlevers.......................................................................................172 Version with locking bar....................................................................................173 • Push the locking bar (1) on the handle (2) down.......................................................173 • Push the locking bar (1) on the handle (2) up.........................................................173 4.6.6 Locking the foot section/releasing the lock...............................................................174 Locking the foot section....................................................................................174 • Align the foot section (1) in such a way that the top connection points (5) are flush.................174 • Bring the lever (2) on the changeover valve to horizontal position, for the top pin...................174 • Press button (3) on the operating panel and extend top pins completely................................174 • Lower the foot section (1) with the auxiliary crane to a position where the lower locking point.......174 • Bring the lever (2) on the changeover valve to vertical position, for the lower pins..................174 • Press button (3) on the operating panel and extend lower pins completely..............................174 • Secure the hydraulic lock; àp.451................................................................174 Releasing the lock..........................................................................................175 • Bring the lever (2) on the changeover valve to horizontal position, for the top pin...................175 4.6.7 Raising/placing the luffing jib...........................................................................176 Raising the luffingjib....................................................................................176 Setting down the luffing control arm.......................................................................177 Raising/folding in railing..................................................................................177 4.6.8 Manual control............................................................................................178 Connecting the hand-held control............................................................................178 Starting the crane engine with the hand-held control........................................................179 p.......................................................................................................179 Moving the hoisting gear....................................................................................179 A B.....................................................................................................179 Turning off crane engine with the hand-held control.........................................................180 Q.......................................................................................................180 Removing the hand-held control..............................................................................180 4.6.9 Separating/joining catcher 2 and raising cylinder.........................................................181 Separating catcher 2 and the raising cylinder...............................................................181 Connecting catcher 2 and raising cylinder...................................................................182 4.6.10 Reeving the auxiliary hoist rope to the upper hookblock.................................................183 4.6.11 Preparing for rigging the upper hook block...............................................................185 Before mounting the foot section............................................................................185 After mounting the foot section.............................................................................186 4.6.12 Securing the upper hook block on the luffing control arm.................................................186 Release the securing device on the upper hook block.........................................................186 Pull the upper hook block towards the luffing control arm...................................................187 Locking the upper hook block...............................................................................188 4.6.13 Removing the upper hook block from the luffing control arm...............................................190 Releasing the locking pin...................................................................................190 Pull the upper hook block towards the catcher...............................................................192 Secure the upper hook block in the catcher..................................................................192 4.6.14 Connecting pins – holders and handling...................................................................193 Holders.....................................................................................................193 Handling the pins.......................................................................................193 4.6.15 Replacing the intermediate sections on the foot section..................................................194 Prerequisites...............................................................................................194 When rigging................................................................................................195 When unrigging..............................................................................................196 4.6.16 Installing/disassembling boom sections and rear pendant links............................................197 Mounting....................................................................................................197 • Sling the previously mounted boom section (1) using an auxiliary crane................................198 • Raise the luffing jib until the bearing points (2) in the lower chord align...........................198 Removal.....................................................................................................199 • Release the connections (2) on both sides in the lower chord..........................................200 • Lower the luffing jib using the auxiliary crane until the released boom section (1) is touching.......200 • Repeat the procedure until only one boom section (1) is left on the intermediate section(2)..........200 • Lift the luffing jib and lock the hinge (2) on the foot section.......................................200 • Dismantle the last boom section (1)...................................................................200 Transport protection rear pendant link....................................................................201 4.6.17 Hinge lock in the foot section...........................................................................202 Releasing the hinge lock...................................................................................202 Locking the hinge...........................................................................................203 4.6.18 Replacing deflection sheaves on the angle piece..........................................................205 • Sling the deflection sheave to the safety roller (1).....................................................205 • Release the retaining pins and remove both pins (2) from the lower brackets (4)...........................205 • Lock the deflection sheave in this position with both pins (2)............................................205 4.6.19 Fold deflection sheaves up/down..........................................................................206 Folding down the deflection sheave.........................................................................206 Folding up the deflection sheave...........................................................................206 Folding support roller on the foot section..................................................................207 • Release the retaining pin and remove the pins (1) from the connection points (4)......................207 • Release the retaining pin and remove the pin (1) from the bore hole (3)...............................207 • Fold the support roller (2) upwards...................................................................207 • Insert the pin (1) into the connecting points (4) and secure it with the retaining pin................207 4.6.20 Setting the angle position of the luffing jib............................................................208 Set angle position of 22...................................................................................209 Set angle position of 0....................................................................................209 4.6.21 Changing the lifting limit switch and anemometer.........................................................210 Changing the lifting limit switch...........................................................................210 Changing anemometer........................................................................................211 4.6.22 Electric connection to the foot section/main boom........................................................212 Establishing a connection...................................................................................212 Detaching the connection....................................................................................213 4.6.23 Electric connection to the head section/foot section.....................................................213 Connecting cable............................................................................................213 Establishing a connection...................................................................................214 Detaching the connection....................................................................................215 4.6.24 Placing and reeving hoist rope...........................................................................216 Possible reeving methods...................................................................................217 4.6.25 Opening the luffing jib submenu..........................................................................219 0...........................................................................................................219 4.6.26 Telescoping with the luffing jib.........................................................................220 Prerequisites...............................................................................................220 è...........................................................................................................220 0...........................................................................................................220 • Press the button beside the symbol Telescopic extension operating mode (2) once. The indicator ...........220 Telescopic extension with teleautomation....................................................................221 Telescoping with semi-automatic.............................................................................223 %.......................................................................................................223 0.......................................................................................................223 $.......................................................................................................223 $.......................................................................................................224 4.6.27 Derricking luffing jib when rigging......................................................................225 Prerequisites...............................................................................................225 0.......................................................................................................225 • Press the button beside the symbol Rigging operating mode (4) once. The indicator lamp in the s.......225 $...................................................................................................225 $...................................................................................................226 $...................................................................................................226 4.6.28 Derricking main boom with installed luffing jib..........................................................227 Derricking between –1.2 to 82.............................................................................227 (...........................................................................................................227 Derricking between 82 and 60..............................................................................228 %.......................................................................................................228 4.6.29 Bringing the luffing jib into working position...........................................................229 Raising luffing jib.........................................................................................229 (.......................................................................................................229 • Slowly carry out the Lift auxiliary hoist movement, in order to raise the luffing control arm.........229 Telescoping to fixed length................................................................................230 &.......................................................................................................230 Lowering to working position................................................................................230 4.6.30 Preparing the luffing jib for unrigging..................................................................231 4.7 Operation with the luffing jib..................................................................................235 %...............................................................................................................235 4.7.1 Crane movements...........................................................................................236 9...........................................................................................................236 4.7.2 Working range and shutdowns..............................................................................237 $...........................................................................................................237 $...........................................................................................................238 4.7.3 SLI shutdown..............................................................................................238 * +.........................................................................................................238 4.7.4 The effect of wind when operating with the luffing jib....................................................239 4.7.5 Troubleshooting and remedy................................................................................241 4.8 Driving with rigged crane and rigged luffing jib...............................................................243 4.8.1 Driving route.............................................................................................243 4.8.2 Rigging modes for moving and axle loads...................................................................244 &...........................................................................................................246 %...........................................................................................................246 Notes on the tables.........................................................................................247 25 m (82 ft) luffing jib....................................................................................247 31 m (102 ft) luffing jib...................................................................................248 37 m (121 ft) luffing jib...................................................................................248 43 m (141 ft) luffing jib...................................................................................249 49 m (161 ft) luffing jib...................................................................................249 55 m (180 ft) luffing jib...................................................................................250 61 m (200 ft) luffing jib...................................................................................250 67 m (220 ft) luffing jib...................................................................................251 73 m (240 ft) luffing jib...................................................................................251 4.8.3 Driving the rigged crane..................................................................................253 Checking the superstructure lock............................................................................253 4.......................................................................................................253 Retracting the outrigger...................................................................................253 Switching over the suspension locking system................................................................253 Driving.....................................................................................................254 Supporting the truck crane.................................................................................255 If necessary, rig the counterweight sections................................................................255 4.9 Luffing jib maintenance.........................................................................................257 4.9.1 Maintenance plans.........................................................................................257 M 1 maintenance plan........................................................................................257 M 3 maintenance plan........................................................................................257 Maintenance schedule Y 2....................................................................................258 Maintenance schedule Y 5....................................................................................258 Maintenance schedule Y 10...................................................................................258 4.9.2 Lubricant table...........................................................................................259 4.9.3 Maintenance work..........................................................................................260 Notes on cleaning work......................................................................................260 Lubricating connecting pins.............................................................................260 4.9.4 Fall-back guard strut maintenance work....................................................................261 Equipment required.........................................................................................261 Test connections............................................................................................262 Nitrogen pressure...........................................................................................262 • Connect the filling hose (3) to the nitrogen bottle...................................................264 • Bleed the filling hose. To do this, open the relief valve (2) and the valve at the nitrogen bot.......264 Oil pressure................................................................................................266 4.9.5 Required inspections for the fall-back guard strut........................................................268 5 Heavy load lattice extension..........................................................................................271 5.1 Components and identification...................................................................................271 Components......................................................................................................271 Identification..................................................................................................272 5.2 Possible combinations...........................................................................................275 5.3 Slinging points.................................................................................................277 5.4 Rigging the heavy load lattice extension........................................................................279 5.4.1 CHECKLIST: Rigging the heavy load lattice extension.......................................................279 5.4.2 CHECKLIST: Unrigging the heavy load lattice extension.....................................................282 5.5 Description of rigging work.....................................................................................285 5.5.1 Truck crane rigging mode during installation of the heavy load lattice extension.........................285 5.5.2 Establishing/disconnecting the connections for the hydraulic lock.........................................286 Establish connections......................................................................................286 Disconnecting connections...................................................................................286 5.5.3 Secure/release hydraulic lock.............................................................................287 Secure lock................................................................................................287 • Push the locking bar (1) on the handle (2) down.......................................................287 Release pins...............................................................................................287 • Push the locking bar (1) on the handle (2) up.........................................................287 5.5.4 Locking the adapter/releasing the lock....................................................................288 Locking the adapter.........................................................................................288 • Bring the lever (2) on the changeover valve to horizontal position, for the top pin...................288 Releasing the lock..........................................................................................289 • Bring the lever (2) on the changeover valve to horizontal position, for the top pin...................289 5.5.5 Connecting pins – holders and handling....................................................................290 Holders.....................................................................................................290 Handling the pins...........................................................................................290 5.5.6 Installing/removing head section and angle piece..........................................................291 Installing..................................................................................................291 Removal.....................................................................................................292 5.5.7 Replacing deflection sheaves on the angle piece...........................................................293 • Sling the deflection sheave to the safety roller (1).....................................................293 • Release the retaining pins and remove both pins (2) from the upper brackets (4)...........................293 5.5.8 Fold deflection sheaves up/down...........................................................................294 Folding down the deflection sheave.........................................................................294 Folding up the deflection sheave...........................................................................294 5.5.9 Setting the angle position of the heavy load lattice extension............................................295 Set angle position of 42...................................................................................296 Set angle position of 20...................................................................................296 5.5.10 Changing the lifting limit switch and anemometer.........................................................297 Changing the lifting limit switch...........................................................................297 Changing anemometer........................................................................................298 5.5.11 Establishing/disconnecting the electrical connection.....................................................299 Locking/unlocking the cable drum............................................................................299 Establish/terminate connection..............................................................................300 5.5.12 Placing and reeving hoist rope...........................................................................301 Possible reeving methods...................................................................................302 5.6 Operation with the heavy load lattice extension.................................................................305 5.6.1 Enter components for heavy load lattice extension on the SLI..............................................305 5.6.2 Telescoping with rigged heavy load lattice extension......................................................306 5.6.3 Crane movements...........................................................................................307 5.6.4 SLI shutdown..............................................................................................307 +...........................................................................................................307 5.6.5 Wind effect when operating the heavy load lattice extension...............................................308 5.7 Turning loads with the heavy load lattice extension.............................................................309 5.7.1 Prerequisites.............................................................................................309 5.7.2 Set SLI for turning the load..............................................................................310 Entering a reeving..........................................................................................310 Set the SLI to the auxiliary hoist..........................................................................311 5.7.3 Turning a load............................................................................................312 5.8 Driving with rigged crane and rigged heavy load lattice extension..............................................315 5.8.1 Driving route.............................................................................................315 5.8.2 Position of the boom and the axle load....................................................................316 4 m (13 ft)-heavy load lattice extension....................................................................318 7.5 m (25 ft) heavy load lattice extension..................................................................319 5.8.3 Driving the rigged crane..................................................................................320 Checking the superstructure lock............................................................................320 4.......................................................................................................320 Retracting the outrigger...................................................................................320 Switching over the suspension locking system................................................................320 Driving.....................................................................................................321 Supporting the truck crane.................................................................................322 If necessary, rig the counterweight sections................................................................322 6 Index.................................................................................................................325 B...................................................................................................................327 C...................................................................................................................328 D...................................................................................................................328 H...................................................................................................................328 I...................................................................................................................328 L...................................................................................................................329 M...................................................................................................................330 P...................................................................................................................330 R...................................................................................................................330 S...................................................................................................................330 T...................................................................................................................330
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