Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3113630 – PDF DOWNLOAD

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Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3113630 – PDF DOWNLOAD

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Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3113630 – PDF DOWNLOAD

Language : English
Pages : 400
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3113630 – PDF DOWNLOAD

Basic safety instructions:

• In principle, all the basic safety instructions from the Operating Instructions
  GMK 4100L-1 are applicable.
• Observe also all safety instructions and warnings on the truck crane!

Other applicable documents:

In addition to the information in this operating manual, all the instructions
in the following sections of the supplied Operating Instructions GMK 4100L-1
are also applicable:
– Intended use
– Improper use
– Organisational measures
– Personnel qualifications

Safety instructions for working with a lattice extension:

• This chapter contains additional safety instructions only for safe use of the lattice extensions
  described in these operating instructions.
• 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 fall arrest systems.
• The points at which the fall arrest system can be attached to on the truck
  crane are indicated by the symbol shown here.

TABLE OF CONTENTS:

Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3113630 – PDF DOWNLOAD

Additional page: Derricking cylinder positionson the swing-away lattice.........................................  3
	Validity....................................................................................................  3
	Reason for the modification.................................................................................  3
	When rigging theswing-away lattice.........................................................................  4
	When rigging theISS........................................................................................  5
1 About these operating instructions............................................................................ 33
	1.1 Validity................................................................................................ 33
		Validity of this operating manual....................................................................... 33
		Prerequisites for installation and operation............................................................ 33
		References to other operating manuals................................................................... 33
	1.2 Terms used.............................................................................................. 34
2 Basic safety instructions..................................................................................... 37
	2.1 Other applicable documents.............................................................................. 37
	2.2 Safety instructions for working with a lattice extension................................................ 38
		Working at heights...................................................................................... 38
		Slinging................................................................................................ 38
		Locks................................................................................................... 38
		Rigging mode............................................................................................ 38
		Two cranes.............................................................................................. 38
3 Operating elements............................................................................................ 39
	3.1 On the lattice extension................................................................................ 39
		3.1.1 Overview.......................................................................................... 39
		3.1.2 Swing-away lattice control unit................................................................... 40
		3.1.3 Drive for telescoping............................................................................. 40
		3.1.4 Connection at rear................................................................................ 41
		3.1.5 Connection in the centre.......................................................................... 41
		3.1.6 Connection in front............................................................................... 42
	3.2 In the crane cab........................................................................................ 43
		3.2.1 Overview.......................................................................................... 43
		3.2.2 On the CCS control unit........................................................................... 44
		3.2.3 On the RCL control unit........................................................................... 47
			Menu for entering rigging mode...................................................................... 47
			Monitoring menu..................................................................................... 47
		3.2.4 At the control console, right..................................................................... 48
	3.3 On the hand-held control unit........................................................................... 49
		3.3.1 Hand-held control connection...................................................................... 51
			Connecting and removing the hand-held control....................................................... 51
4 Rigging work on the main boom................................................................................. 53
	4.1 Hose drum............................................................................................... 53
		4.1.1 Slinging points................................................................................... 53
		4.1.2 Transport dimensions and weights.................................................................. 54
	4.2 Rigging work on the hose drum........................................................................... 55
		4.2.1 Fitting/removing the hose drum.................................................................... 55
			Installation........................................................................................ 55
			Removing............................................................................................ 56
		4.2.2 Checking the locking device on the hose drum...................................................... 57
		4.2.3 Positions of the hydraulic connections.......................................................... 58
			Working with the lattice extension.................................................................. 58
			Main boom operation................................................................................. 59
5 Swing-away lattice............................................................................................ 61
	5.1 Notes on this chapter................................................................................... 61
	5.2 Operations planning..................................................................................... 62
		5.2.1 Assembly.......................................................................................... 62
		5.2.2 Identification.................................................................................... 63
		5.2.3 Slinging points................................................................................... 64
			Section1 and section2............................................................................. 64
			Section3........................................................................................... 64
			Section combination................................................................................. 65
		5.2.4 Transport dimensions and weights.................................................................. 66
		5.2.5 Transport condition – removed..................................................................... 67
			On the swing- away lattice.......................................................................... 68
			On the main boom.................................................................................... 69
		5.2.6 Transport condition – folded...................................................................... 70
	5.3 Checklists for rigging work............................................................................. 73
		5.3.1 Overview.......................................................................................... 73
		5.3.2 CHECKLIST: Installing the swing-away lattice – into the working position.......................... 75
		5.3.3 CHECKLIST: Installing the swing-away lattice – into the transport position........................ 79
		5.3.4 CHECKLIST: Removing the swing-away lattice – from the working position............................ 85
		5.3.5 CHECKLIST: Removing the swing-away lattice – from the transport position.......................... 89
		5.3.6 CHECKLIST: Rigging the swing-away lattice – into the working position............................. 95
		5.3.7 CHECKLIST: Rigging the swing-away lattice – into the transport position...........................101
		5.3.8 CHECKLIST: Subsequent necessary rigging work......................................................107
		5.3.9 CHECKLIST: Preliminary unrigging work.............................................................109
	5.4 Rigging work............................................................................................111
		5.4.1 Securing the swing-away lattice with guide ropes..................................................111
		5.4.2 Notes on the position of the telescoping cylinder.................................................112
		5.4.3 Establishing/separating the rear connection.......................................................113
			Connecting..........................................................................................113
			Disconnecting.......................................................................................113
		5.4.4 Establishing/releasing the centre connection......................................................114
			Connecting..........................................................................................114
			Disconnecting.......................................................................................114
		5.4.5 Establishing/releasing the front connection.......................................................115
			Connecting..........................................................................................115
			Disconnecting.......................................................................................115
		5.4.6 Making/disconnecting the slewing connection.......................................................116
			Connecting..........................................................................................116
			Disconnecting.......................................................................................116
		5.4.7 Slewing cylinder into the telescoping/transport position..........................................117
		5.4.8 Derricking cylinder positions.....................................................................118
			Part 3 without head sheave..........................................................................118
			Part 3 with head sheave.............................................................................119
		5.4.9 Folding out/folding in the deflection sheave......................................................120
			Folding out.........................................................................................120
			Folding in..........................................................................................121
		5.4.10 Establishing/disconnecting the hydraulic connections – Mainboom/swing-away lattice..............123
		5.4.11 Establishing/disconnecting electrical connections................................................124
			Connecting..........................................................................................124
			Disconnecting.......................................................................................125
		5.4.12 Relieving the connecting points..................................................................126
		5.4.13 Swinging the swing-away lattice when rigging.....................................................127
			When rigging inthe working position................................................................127
			When rigging in the transport position..............................................................127
		5.4.14 Connections on the left/right of the main boom head..............................................129
			Establishing connections............................................................................129
			Separating connections..............................................................................130
		5.4.15 Retracting/extending section1...................................................................131
			Prerequisite:.......................................................................................131
			Retracting..........................................................................................131
			Extending...........................................................................................134
		5.4.16 Attaching/removing the hoist rope................................................................138
			Fitting with swing-away lattices A and B............................................................138
			Removing with swing-away lattices A and B...........................................................140
			Possible reeving methods............................................................................141
		5.4.17 Installing/removing the lifting limit switch.....................................................142
			Installation........................................................................................142
			Removing............................................................................................142
		5.4.18 Installing/removing the anemometer and air traffic control light.................................143
			Installation........................................................................................143
			Removing............................................................................................143
		5.4.19 Installing / removing the camera.................................................................144
			Installation........................................................................................144
			Removing............................................................................................144
		5.4.20 Derricking the swing-away lattice for rigging work – hand-held control...........................145
		5.4.21 Derricking the swing-away lattice for rigging work – Section3 control unit......................146
		5.4.22 Main boom operation with a folded swing-away lattice – Necessary rigging work....................147
			Before telescoping out..............................................................................147
			After telescoping in................................................................................148
	5.5 Operation with swing-away lattice.......................................................................149
		5.5.1 Setting the RCL...................................................................................149
			Input...............................................................................................149
			Shutdown............................................................................................150
		5.5.2 Derricking the main boom..........................................................................150
			Slewing range of360...............................................................................150
		5.5.3 Telescoping with rigged swing-away lattice........................................................151
			Slewing range of360...............................................................................151
		5.5.4 Derricking the swing-away lattice in operation....................................................151
			Switching on the derricking gear...................................................................151
			Raising and lowering................................................................................152
			Switching off the derricking gear...................................................................152
		5.5.5 Procedure if permissible wind speed is exceeded...................................................153
		5.5.6 Information about the main boom operation when the swing- away lattice is folded/rigged...........154
			Folded..............................................................................................154
			In working position.................................................................................154
		5.5.7 Instructions for turning loads over...............................................................155
	5.6 Maintenance.............................................................................................157
		5.6.5 Description of maintenance work...................................................................159
			Pins................................................................................................159
			Connections.........................................................................................160
			Rollers.............................................................................................161
			Hydraulic cylinder..................................................................................162
			Joints..............................................................................................163
			Chain drive.........................................................................................164
	5.7 Finding and eliminating malfunctions....................................................................169
		5.7.1 Troubleshooting table.............................................................................169
		5.7.2 Swing-away lattice emergency operation............................................................171
			Before telescoping out..............................................................................171
			Retract.............................................................................................173
			After telescoping in...............................................................................173
6 Boom extension................................................................................................175
	6.1 Operations planning.....................................................................................175
		6.1.1 Assembly..........................................................................................175
		6.1.2 Identification....................................................................................176
			Section4...........................................................................................176
		6.1.3 Slinging points...................................................................................177
			Section4...........................................................................................177
		6.1.4 Transport dimensions and weights..................................................................178
		6.1.5 Transport condition...............................................................................178
			Section4...........................................................................................178
	6.2 Checklists for rigging work.............................................................................179
		6.2.1 Overview..........................................................................................179
		6.2.2 CHECKLIST: Installing the boom extension..........................................................180
		6.2.3 CHECKLIST: Removing the boom extension............................................................184
	6.3 Description of the rigging work.........................................................................189
		6.3.1 Folding the deflection sheave out/in – section4..................................................189
		6.3.2 Mounting section4 to the main boom / removing it from the main boom..............................190
		6.3.3 Making/breaking the electrical connections – section4 / mainboom................................191
		6.3.4 Making/breaking the hydraulic connections– section4 / mainboom..................................193
		6.3.5 Connecting/disconnecting the electrical connections – section4/swing-away lattice................194
		6.3.6 Connecting/disconnecting the hydraulic connections – section4/swing-away lattice.................196
		6.3.7 Installing/removing the swing-away lattice to/from section4......................................197
		6.3.8 Attaching/removing the hoist rope.................................................................198
			Possible reeving methods............................................................................200
	6.4 Operation with boom extension...........................................................................201
		6.4.1 Setting the RCL...................................................................................201
			Input...............................................................................................201
			Shutdown............................................................................................202
		6.4.2 Derricking, telescoping the main boom.............................................................202
			Slewing range of360...............................................................................202
		6.4.3 Procedure if permissible wind speed is exceeded...................................................203
		6.4.4 Instructions for turning loads over...............................................................203
	6.5 Maintenance.............................................................................................204
		6.5.3 Description of maintenance work...................................................................205
7 Heavy load lattice extension (SLS) 2.0m (6.6ft).............................................................207
	7.1 Operations planning.....................................................................................207
		7.1.1 Assembly..........................................................................................207
		7.1.2 Identification....................................................................................208
			Section6...........................................................................................208
		7.1.3 Slinging points...................................................................................209
			Section6...........................................................................................209
		7.1.4 Transport dimensions and weights..................................................................210
		7.1.5 Transport condition...............................................................................210
			Section6...........................................................................................210
	7.2 Checklists for rigging work.............................................................................213
		7.2.1 Overview..........................................................................................213
		7.2.2 CHECKLIST: Installing SLS 2.0m (6.6 ft) – in working position....................................214
		7.2.3 CHECKLIST: Installing SLS 2.0m (6.6 ft) – in transport position..................................217
		7.2.4 CHECKLIST: Removing SLS 2.0m (6.6 ft) – in working position......................................218
		7.2.5 CHECKLIST: Removing SLS 2.0m (6.6 ft) – in transport position....................................221
		7.2.6 CHECKLIST: Rigging SLS 2.0m (6.6 ft) – in working position.......................................223
		7.2.7 CHECKLIST: Rigging SLS 2.0m (6.6 ft) – in transport position.....................................227
	7.3 Rigging work............................................................................................229
		7.3.1 Mounting section6 to the main boom / removing it from the main boom..............................229
			Installing..........................................................................................229
			Removing............................................................................................230
		7.3.2 Moving section6 into the working position / transport position...................................232
			In working position.................................................................................232
			In transport position...............................................................................234
		7.3.3 Making/breaking the electrical connections – section6 / mainboom................................236
			Connecting..........................................................................................236
			Disconnecting.......................................................................................236
		7.3.4 Positioning/removing the hoist rope – section6...................................................237
		7.3.5 Possible reeving methods on the heavy load lattice extension......................................238
		7.3.6 Installing / removing the lifting limit switch and anemometer.....................................240
			Lifting limit switch................................................................................240
			Anemometer..........................................................................................241
		7.3.7 Installing / removing the camera..................................................................241
		7.3.8 Setting the angle.................................................................................242
	7.4 Operating the heavy load lattice extension..............................................................243
		7.4.1 Setting the RCL...................................................................................243
			Input...............................................................................................243
			Shutdown............................................................................................243
		7.4.2 Derricking, telescoping the main boom.............................................................244
			Slewing range of360...............................................................................244
		7.4.3 Procedure if permissible wind speeds are exceeded.................................................245
		7.4.4 Instructions for turning loads over...............................................................245
	7.5 Maintenance.............................................................................................247
		7.5.3 Description of maintenance work...................................................................248
8 Integral heavy load lattice extension (ISS) 3.3/11.3m (10.8/37.0)ft)........................................249
	8.1 Operations planning.....................................................................................250
		8.1.1 Assembly..........................................................................................250
		8.1.2 Identification....................................................................................251
			Section3...........................................................................................251
			Section4...........................................................................................251
		8.1.3 Slinging points...................................................................................252
			Section3...........................................................................................252
			Section4...........................................................................................252
		8.1.4 Transport dimensions and weights..................................................................253
		8.1.5 Transport condition...............................................................................253
			Section3...........................................................................................253
			Section4...........................................................................................254
	8.2 Checklists for rigging work.............................................................................255
		8.2.1 Supervision.......................................................................................255
		8.2.2 CHECKLIST: Installing the ISS 3.3 m (10.8 ft) – in working position...............................256
		8.2.3 CHECKLIST: Remove the ISS 3.3m (10.8 ft) – from the working position.............................260
		8.2.4 CHECKLIST: Swing the ISS 3.3m (10.8 ft) away from the swing-away lattice – rig it in worki.......264
		8.2.5 CHECKLIST: Rigging the ISS 3.3m (10.8 ft) from the swing-away lattice – in transport position....271
		8.2.6 CHECKLIST: Installing the ISS 11.3m (37.0ft)....................................................276
		8.2.7 CHECKLIST: Removing the ISS 11.3m (37.0ft)......................................................281
	8.3 Rigging work............................................................................................287
		8.3.1 Releasing the connections – section3/section2...................................................287
			From the working position...........................................................................287
			On the ground.......................................................................................288
		8.3.2 Locking the connection – section3/section2......................................................291
			From the working position...........................................................................291
			On the ground.......................................................................................293
		8.3.3 Installing/removing section3.....................................................................296
		8.3.4 Establishing/parting the slewing connection.......................................................297
			Establishing........................................................................................297
			Disconnecting.......................................................................................297
		8.3.5 Locking/releasing connections – section 3/main boom...............................................298
			Establishing connections............................................................................298
			Separating connections..............................................................................299
		8.3.6 Making/breaking the electrical connections – section3 / mainboom................................300
		8.3.7 Making/breaking the hydraulic connections – section3 / mainboom.................................302
		8.3.8 Folding the deflection sheave out/in – section3..................................................303
			Folding out.........................................................................................303
			Folding in..........................................................................................303
		8.3.9 Swinging the ISS when rigging.....................................................................305
			When rigging into the working position..............................................................305
			When rigging in the transport position..............................................................305
		8.3.10 Tilt cylinder in the telescoping/transport position..............................................307
		8.3.11 Derricking cylinder positions....................................................................308
		8.3.12 Derricking cylinder positions....................................................................308
		8.3.13 Folding out / folding in the head sheave on section3............................................311
		8.3.14 Attaching/removing the hoist rope................................................................312
			ISS 3.3m (10.8ft).................................................................................312
			ISS 11.3m (37.0ft)................................................................................313
		8.3.15 Possible reeving methods.........................................................................315
		8.3.16 Installing / removing the lifting limit switch...................................................317
			Installation........................................................................................317
			Removing............................................................................................317
		8.3.17 Installing / removing the anemometer and air traffic control light...............................318
			Installation........................................................................................318
			Removing............................................................................................319
		8.3.18 Installing / removing the camera.................................................................320
		8.3.19 Folding out / folding in the deflection sheave on section4......................................321
		8.3.20 Mounting section4 to the main boom / removing it from the main boom.............................322
		8.3.21 Making/breaking the electrical connections – section4 / mainboom...............................324
		8.3.22 Making the electrical connections between section3 and section2................................326
		8.3.23 Making/breaking the hydraulic connections – section4 / mainboom................................328
		8.3.24 Installing/removing section3 on section4.......................................................329
		8.3.25 Making the electrical connections between section4 and section3................................330
		8.3.26 Establishing/parting the hydraulic connection – section4/ section3.............................332
		8.3.27 Derricking the ISS for rigging work – hand-held control..........................................333
		8.3.28 Derricking the ISS for rigging work – Section3 control unit.....................................334
	8.4 ISS, derricking.........................................................................................335
		Switching on the derricking gear.......................................................................335
		Raising and lowering....................................................................................335
		Switching off the derricking gear.......................................................................336
	8.5 Operation with the ISS..................................................................................337
		8.5.1 Setting the RCL...................................................................................337
			Input...............................................................................................337
			Shutdown............................................................................................338
		8.5.2 Derricking, telescoping the main boom.............................................................339
			Slewing range of360...............................................................................339
		8.5.3 Procedure if permissible wind speeds are exceeded.................................................340
		8.5.4 Instructions for turning loads over...............................................................340
	8.6 Maintenance.............................................................................................341
		8.6.5 Description of maintenance work...................................................................343
			Pins................................................................................................343
			Rollers.............................................................................................345
			Hydraulic cylinder..................................................................................346
			Joints..............................................................................................347
9 Auxiliary single-sheave boom top..............................................................................349
	9.1 Operations planning.....................................................................................349
		9.1.1 Identification and slinging points................................................................349
		9.1.2 Transport dimensions and weights..................................................................350
		9.1.3 Transport condition...............................................................................350
	9.2 Rigging work............................................................................................351
		9.2.1 Moving the auxiliary single-sheave boom top into the working position.............................351
		9.2.2 Moving the auxiliary single-sheave boom top into the transport position...........................354
		9.2.3 Installing/removing a folded up auxiliary single-sheave boom top..................................357
		9.2.4 Attaching and removing the hoist rope.............................................................359
			Possible reeving methods............................................................................359
		9.2.5 Installing / removing the lifting limit switch and anemometer.....................................361
			Lifting limit switch................................................................................361
			Anemometer..........................................................................................362
		9.2.6 Installing / removing the camera..................................................................362
	9.3 Operation with the auxiliary single-sheave boom top.....................................................363
		9.3.1 Setting the RCL...................................................................................363
			Input...............................................................................................363
			Shutdown............................................................................................363
		9.3.2 Procedure if permissible wind speeds are exceeded.................................................364
		9.3.3 Instructions for turning loads over...............................................................364
	9.4 Maintenance.............................................................................................365
		9.4.3 Description of maintenance work...................................................................366
10 Turning loads over...........................................................................................367
	Prerequisites...............................................................................................367
	10.1 Setting the RCL........................................................................................368
		Entering the reeving....................................................................................368
		Switching over to the auxiliary hoist...................................................................368
	10.2 Turning a load over....................................................................................369
11 Driving with a rigged crane..................................................................................371
	11.1 Safety instructions....................................................................................371
	11.2 Route..................................................................................................372
	11.3 Permissible rigging modes and axle loads...............................................................373
		Information about the tables............................................................................373
		11.3.1 Swing-away lattice...............................................................................374
			Swing-away lattice 1.7 + 9.4m (5.6 + 30.8ft)......................................................374
			Swing-away lattice 1.7 + 15.9m (5.6 + 52.2ft).....................................................376
		11.3.2 Boom extension...................................................................................378
			Boom extension 9.7+ 9.4m (31.8 + 30.8ft)..........................................................378
			Boom extension 9.7+ 15.9m (31.8 + 52.2ft).........................................................380
		11.3.3 Heavy load lattice extension (SLS)...............................................................382
			Heavy load lattice extension 0.46m + 1.46 m (0.6ft + 4.8 ft)......................................382
		11.3.4 Heavy load lattice extension (ISS)...............................................................384
			Heavy load lattice extension 1.7m + 1.6m (5.6ft + 5.2ft)........................................384
			Heavy load lattice extension 9.7m + 1.6m (26.6ft + 5.2ft).......................................386
		11.3.5 Auxiliary single-sheave boom top.................................................................388
	11.4 Before driving.........................................................................................389
	11.5 Whilst driving.........................................................................................389
	11.6 After driving..........................................................................................389
12 Index........................................................................................................391
	A...........................................................................................................393
	B...........................................................................................................393
	D...........................................................................................................394
	H...........................................................................................................394
	I...........................................................................................................395
	L...........................................................................................................396
	M...........................................................................................................396
	O...........................................................................................................396
	P...........................................................................................................396
	R...........................................................................................................396
	S...........................................................................................................396
	T...........................................................................................................397

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• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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