Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3302629 – PDF DOWNLOAD

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Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3302629 – PDF DOWNLOAD

FILE DETAILS:

Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3302629 – PDF DOWNLOAD

Language : English
Pages : 396
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3302629 – 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

TABLE OF CONTENTS:

Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3302629 – PDF DOWNLOAD

1 About these operating instructions.......................................................................... 29
	1.1 Validity.............................................................................................. 29
		Validity of this operating manual..................................................................... 29
		Prerequisites for installation and operation.......................................................... 29
		References to other operating manuals................................................................. 29
	1.2 Terms used............................................................................................ 30
2 Basic safety instructions................................................................................... 33
	2.1 Other applicable documents............................................................................ 33
	2.2 Safety instructions for working with a lattice extension.............................................. 34
		Working at heights.................................................................................... 34
		Slinging.............................................................................................. 34
		Locks................................................................................................. 34
		Rigging mode.......................................................................................... 34
		Two cranes............................................................................................ 34
3 Operating elements.......................................................................................... 35
	3.1 On the lattice extension.............................................................................. 35
		3.1.1 Overview........................................................................................ 35
		3.1.2 Swing-away lattice control unit................................................................. 36
		3.1.3 Drive for telescoping........................................................................... 36
		3.1.4 Connection at rear.............................................................................. 37
		3.1.5 Connection in the centre........................................................................ 37
		3.1.6 Connection in front............................................................................. 38
	3.2 In the crane cab...................................................................................... 39
		3.2.1 Overview........................................................................................ 39
		3.2.2 On the CCS control unit......................................................................... 40
		3.2.3 On the RCL control unit......................................................................... 43
			Menu for entering rigging mode.................................................................... 43
			Monitoring menu................................................................................... 43
		3.2.4 At the control console, right................................................................... 44
	3.3 On the hand-held control unit......................................................................... 45
		3.3.1 Hand-held control connection.................................................................... 47
			Connecting and removing the hand-held control..................................................... 47
4 Rigging work on the main boom............................................................................... 49
	4.1 Hose drum............................................................................................. 49
		4.1.1 Slinging points................................................................................. 49
		4.1.2 Transport dimensions and weights................................................................ 50
	4.2 Rigging work on the hose drum......................................................................... 51
		4.2.1 Fitting/removing the hose drum.................................................................. 51
			Installation...................................................................................... 51
			Removing.......................................................................................... 52
		4.2.2 Checking the locking device on the hose drum.................................................... 53
		4.2.3 Positions of the hydraulic connections........................................................ 54
			Working with the lattice extension................................................................ 54
			Main boom operation............................................................................... 55
5 Swing-away lattice.......................................................................................... 57
	5.1 Notes on this chapter................................................................................. 57
	5.2 Operations planning................................................................................... 58
		5.2.1 Assembly........................................................................................ 58
		5.2.2 Identification.................................................................................. 59
		5.2.3 Slinging points................................................................................. 60
			Section1 and section2........................................................................... 60
			Section3......................................................................................... 60
			Section combination............................................................................... 61
		5.2.4 Transport dimensions and weights................................................................ 62
		5.2.5 Transport condition – removed................................................................... 63
			On the swing- away lattice........................................................................ 64
			On the main boom.................................................................................. 65
		5.2.6 Transport condition – folded.................................................................... 66
	5.3 Checklists for rigging work........................................................................... 69
		5.3.1 Overview........................................................................................ 69
		5.3.2 CHECKLIST: Installing the swing-away lattice – into the working position........................ 71
		5.3.3 CHECKLIST: Installing the swing-away lattice – into the transport position...................... 75
		5.3.4 CHECKLIST: Removing the swing-away lattice – from the working position.......................... 81
		5.3.5 CHECKLIST: Removing the swing-away lattice – from the transport position........................ 85
		5.3.6 CHECKLIST: Rigging the swing-away lattice – into the working position........................... 91
		5.3.7 CHECKLIST: Rigging the swing-away lattice – into the transport position......................... 97
		5.3.8 CHECKLIST: Subsequent necessary rigging work....................................................103
		5.3.9 CHECKLIST: Preliminary unrigging work...........................................................105
	5.4 Rigging work..........................................................................................107
		5.4.1 Securing the swing-away lattice with guide ropes................................................107
		5.4.2 Notes on the position of the telescoping cylinder...............................................108
		5.4.3 Establishing/separating the rear connection.....................................................109
			Connecting........................................................................................109
			Disconnecting.....................................................................................109
		5.4.4 Establishing/releasing the centre connection....................................................110
			Connecting........................................................................................110
			Disconnecting.....................................................................................110
		5.4.5 Establishing/releasing the front connection.....................................................111
			Connecting........................................................................................111
			Disconnecting.....................................................................................111
		5.4.6 Making/disconnecting the slewing connection.....................................................112
			Connecting........................................................................................112
			Disconnecting.....................................................................................112
		5.4.7 Slewing cylinder into the telescoping/transport position........................................113
		5.4.8 Derricking cylinder positions...................................................................114
			Part 3 without head sheave........................................................................114
			Part 3 with head sheave...........................................................................115
		5.4.9 Folding out/folding in the deflection sheave....................................................116
			Folding out.......................................................................................116
			Folding in........................................................................................117
		5.4.10 Establishing/disconnecting the hydraulic connections – Mainboom/swing-away lattice............119
		5.4.11 Establishing/disconnecting electrical connections..............................................120
			Connecting........................................................................................120
			Disconnecting.....................................................................................121
		5.4.12 Relieving the connecting points................................................................122
		5.4.13 Swinging the swing-away lattice when rigging...................................................123
			When rigging inthe working position..............................................................123
			When rigging in the transport position............................................................123
		5.4.14 Connections on the left/right of the main boom head............................................125
			Establishing connections..........................................................................125
			Separating connections............................................................................126
		5.4.15 Retracting/extending section1.................................................................127
			Prerequisite:.....................................................................................127
			Retracting........................................................................................127
			Extending.........................................................................................130
		5.4.16 Attaching/removing the hoist rope..............................................................134
			Fitting with swing-away lattices A and B..........................................................134
			Removing with swing-away lattices A and B.........................................................136
			Possible reeving methods..........................................................................137
		5.4.17 Installing/removing the lifting limit switch...................................................138
			Installation......................................................................................138
			Removing..........................................................................................138
		5.4.18 Installing/removing the anemometer and air traffic control light...............................139
			Installation......................................................................................139
			Removing..........................................................................................139
		5.4.19 Installing / removing the camera...............................................................140
			Installation......................................................................................140
			Removing..........................................................................................140
		5.4.20 Derricking the swing-away lattice for rigging work – hand-held control.........................141
		5.4.21 Derricking the swing-away lattice for rigging work – Section3 control unit....................142
		5.4.22 Main boom operation with a folded swing-away lattice – Necessary rigging work..................143
			Before telescoping out............................................................................143
			After telescoping in..............................................................................144
	5.5 Operation with swing-away lattice.....................................................................145
		5.5.1 Setting the RCL.................................................................................145
			Input.............................................................................................145
			Shutdown..........................................................................................146
		5.5.2 Derricking the main boom........................................................................146
			Slewing range of360.............................................................................146
		5.5.3 Telescoping with rigged swing-away lattice......................................................147
			Slewing range of360.............................................................................147
		5.5.4 Derricking the swing-away lattice in operation..................................................147
			Switching on the derricking gear.................................................................147
			Raising and lowering..............................................................................148
			Switching off the derricking gear.................................................................148
		5.5.5 Procedure if permissible wind speed is exceeded.................................................149
		5.5.6 Information about the main boom operation when the swing- away lattice is folded/rigged.........150
			Folded............................................................................................150
			In working position...............................................................................150
		5.5.7 Instructions for turning loads over.............................................................151
	5.6 Maintenance...........................................................................................153
		5.6.5 Description of maintenance work.................................................................155
			Pins..............................................................................................155
			Connections.......................................................................................156
			Rollers...........................................................................................157
			Hydraulic cylinder................................................................................158
			Joints............................................................................................159
			Chain drive.......................................................................................160
	5.7 Finding and eliminating malfunctions..................................................................165
		5.7.1 Troubleshooting table...........................................................................165
		5.7.2 Swing-away lattice emergency operation..........................................................167
			Before telescoping out............................................................................167
			Retract...........................................................................................169
			After telescoping in.............................................................................169
6 Boom extension..............................................................................................171
	6.1 Operations planning...................................................................................171
		6.1.1 Assembly........................................................................................171
		6.1.2 Identification..................................................................................172
			Section4.........................................................................................172
		6.1.3 Slinging points.................................................................................173
			Section4.........................................................................................173
		6.1.4 Transport dimensions and weights................................................................174
		6.1.5 Transport condition.............................................................................174
			Section4.........................................................................................174
	6.2 Checklists for rigging work...........................................................................175
		6.2.1 Overview........................................................................................175
		6.2.2 CHECKLIST: Installing the boom extension........................................................176
		6.2.3 CHECKLIST: Removing the boom extension..........................................................180
	6.3 Description of the rigging work.......................................................................185
		6.3.1 Folding the deflection sheave out/in – section4................................................185
		6.3.2 Mounting section4 to the main boom / removing it from the main boom............................186
		6.3.3 Making/breaking the electrical connections – section4 / mainboom..............................187
		6.3.4 Making/breaking the hydraulic connections– section4 / mainboom................................189
		6.3.5 Connecting/disconnecting the electrical connections – section4/swing-away lattice..............190
		6.3.6 Connecting/disconnecting the hydraulic connections – section4/swing-away lattice...............192
		6.3.7 Installing/removing the swing-away lattice to/from section4....................................193
		6.3.8 Attaching/removing the hoist rope...............................................................194
			Possible reeving methods..........................................................................196
	6.4 Operation with boom extension.........................................................................197
		6.4.1 Setting the RCL.................................................................................197
			Input.............................................................................................197
			Shutdown..........................................................................................198
		6.4.2 Derricking, telescoping the main boom...........................................................198
			Slewing range of360.............................................................................198
		6.4.3 Procedure if permissible wind speed is exceeded.................................................199
		6.4.4 Instructions for turning loads over.............................................................199
	6.5 Maintenance...........................................................................................200
		6.5.3 Description of maintenance work.................................................................201
7 Heavy load lattice extension (SLS) 2.0m....................................................................203
	7.1 Operations planning...................................................................................203
		7.1.1 Assembly........................................................................................203
		7.1.2 Identification..................................................................................204
			Section6.........................................................................................204
		7.1.3 Slinging points.................................................................................205
			Section6.........................................................................................205
		7.1.4 Transport dimensions and weights................................................................206
		7.1.5 Transport condition.............................................................................206
			Section6.........................................................................................206
	7.2 Checklists for rigging work...........................................................................209
		7.2.1 Overview........................................................................................209
		7.2.2 CHECKLIST: Installing SLS 2.0m – in working position...........................................210
		7.2.3 CHECKLIST: Installing SLS 2.0m – in transport position.........................................213
		7.2.4 CHECKLIST: Removing SLS 2.0m – in working position.............................................214
		7.2.5 CHECKLIST: Removing SLS 2.0m – in transport position...........................................217
		7.2.6 CHECKLIST: Rigging SLS 2.0m – in working position..............................................219
		7.2.7 CHECKLIST: Rigging SLS 2.0m – in transport position............................................223
	7.3 Rigging work..........................................................................................225
		7.3.1 Mounting section6 to the main boom / removing it from the main boom............................225
			Installing........................................................................................225
			Removing..........................................................................................226
		7.3.2 Moving section6 into the working position / transport position.................................228
			In working position...............................................................................228
			In transport position.............................................................................230
		7.3.3 Making/breaking the electrical connections – section6 / mainboom..............................232
			Connecting........................................................................................232
			Disconnecting.....................................................................................232
		7.3.4 Positioning/removing the hoist rope – section6.................................................233
		7.3.5 Possible reeving methods on the heavy load lattice extension....................................234
		7.3.6 Installing / removing the lifting limit switch and anemometer...................................236
			Lifting limit switch..............................................................................236
			Anemometer........................................................................................237
		7.3.7 Installing / removing the camera................................................................237
		7.3.8 Setting the angle...............................................................................238
	7.4 Operating the heavy load lattice extension............................................................239
		7.4.1 Setting the RCL.................................................................................239
			Input.............................................................................................239
			Shutdown..........................................................................................239
		7.4.2 Derricking, telescoping the main boom...........................................................240
			Slewing range of360.............................................................................240
		7.4.3 Procedure if permissible wind speeds are exceeded...............................................241
		7.4.4 Instructions for turning loads over.............................................................241
	7.5 Maintenance...........................................................................................243
		7.5.3 Description of maintenance work.................................................................244
8 Integral heavy load lattice extension (ISS) 3.3/11.3m.....................................................245
	8.1 Operations planning...................................................................................246
		8.1.1 Assembly........................................................................................246
		8.1.2 Identification..................................................................................247
			Section3.........................................................................................247
			Section4.........................................................................................247
		8.1.3 Slinging points.................................................................................248
			Section3.........................................................................................248
			Section4.........................................................................................248
		8.1.4 Transport dimensions and weights................................................................249
		8.1.5 Transport condition.............................................................................249
			Section3.........................................................................................249
			Section4.........................................................................................250
	8.2 Checklists for rigging work...........................................................................251
		8.2.1 Supervision.....................................................................................251
		8.2.2 CHECKLIST: Installing the ISS 3.3 m – in working position.......................................252
		8.2.3 CHECKLIST: Remove the ISS 3.3m – from the working position.....................................256
		8.2.4 CHECKLIST: Swing the ISS 3.3m away from the swing-away lattice – rig it in working position....260
		8.2.5 CHECKLIST: Rigging the ISS 3.3m from the swing- away lattice – in transport position...........267
		8.2.6 CHECKLIST: Installing the ISS 11.3m............................................................272
		8.2.7 CHECKLIST: Removing the ISS 11.3m..............................................................277
	8.3 Rigging work..........................................................................................283
		8.3.1 Releasing the connections – section3/section2.................................................283
			From the working position.........................................................................283
			On the ground.....................................................................................284
		8.3.2 Locking the connection – section3/section2....................................................287
			From the working position.........................................................................287
			On the ground.....................................................................................289
		8.3.3 Installing/removing section3...................................................................292
		8.3.4 Establishing/parting the slewing connection.....................................................293
			Establishing......................................................................................293
			Disconnecting.....................................................................................293
		8.3.5 Locking/releasing connections – section 3/main boom.............................................294
			Establishing connections..........................................................................294
			Separating connections............................................................................295
		8.3.6 Making/breaking the electrical connections – section3 / mainboom..............................296
		8.3.7 Making/breaking the hydraulic connections – section3 / mainboom...............................298
		8.3.8 Folding the deflection sheave out/in – section3................................................299
			Folding out.......................................................................................299
			Folding in........................................................................................299
		8.3.9 Swinging the ISS when rigging...................................................................301
			When rigging into the working position............................................................301
			When rigging in the transport position............................................................301
		8.3.10 Tilt cylinder in the telescoping/transport position............................................303
		8.3.11 Derricking cylinder positions..................................................................304
		8.3.12 Derricking cylinder positions..................................................................304
		8.3.13 Folding out / folding in the head sheave on section3..........................................307
		8.3.14 Attaching/removing the hoist rope..............................................................308
			ISS 3.3m.........................................................................................308
			ISS 11.3m........................................................................................309
		8.3.15 Possible reeving methods.......................................................................311
		8.3.16 Installing / removing the lifting limit switch.................................................313
			Installation......................................................................................313
			Removing..........................................................................................313
		8.3.17 Installing / removing the anemometer and air traffic control light.............................314
			Installation......................................................................................314
			Removing..........................................................................................315
		8.3.18 Installing / removing the camera...............................................................316
		8.3.19 Folding out / folding in the deflection sheave on section4....................................317
		8.3.20 Mounting section4 to the main boom / removing it from the main boom...........................318
		8.3.21 Making/breaking the electrical connections – section4 / mainboom.............................320
		8.3.22 Making the electrical connections between section3 and section2..............................322
		8.3.23 Making/breaking the hydraulic connections – section4 / mainboom..............................324
		8.3.24 Installing/removing section3 on section4.....................................................325
		8.3.25 Making the electrical connections between section4 and section3..............................326
		8.3.26 Establishing/parting the hydraulic connection – section4/ section3...........................328
		8.3.27 Derricking the ISS for rigging work – hand-held control........................................329
		8.3.28 Derricking the ISS for rigging work – Section3 control unit...................................330
	8.4 ISS, derricking.......................................................................................331
		Switching on the derricking gear.....................................................................331
		Raising and lowering..................................................................................331
		Switching off the derricking gear.....................................................................332
	8.5 Operation with the ISS................................................................................333
		8.5.1 Setting the RCL.................................................................................333
			Input.............................................................................................333
			Shutdown..........................................................................................334
		8.5.2 Derricking, telescoping the main boom...........................................................335
			Slewing range of360.............................................................................335
		8.5.3 Procedure if permissible wind speeds are exceeded...............................................336
		8.5.4 Instructions for turning loads over.............................................................336
	8.6 Maintenance...........................................................................................337
		8.6.5 Description of maintenance work.................................................................339
			Pins..............................................................................................339
			Rollers...........................................................................................341
			Hydraulic cylinder................................................................................342
			Joints............................................................................................343
9 Auxiliary single-sheave boom top............................................................................345
	9.1 Operations planning...................................................................................345
		9.1.1 Identification and slinging points..............................................................345
		9.1.2 Transport dimensions and weights................................................................346
		9.1.3 Transport condition.............................................................................346
	9.2 Rigging work..........................................................................................347
		9.2.1 Moving the auxiliary single-sheave boom top into the working position...........................347
		9.2.2 Moving the auxiliary single-sheave boom top into the transport position.........................350
		9.2.3 Installing/removing a folded up auxiliary single-sheave boom top................................353
		9.2.4 Attaching and removing the hoist rope...........................................................355
			Possible reeving methods..........................................................................355
		9.2.5 Installing / removing the lifting limit switch and anemometer...................................357
			Lifting limit switch..............................................................................357
			Anemometer........................................................................................358
		9.2.6 Installing / removing the camera................................................................358
	9.3 Operation with the auxiliary single-sheave boom top...................................................359
		9.3.1 Setting the RCL.................................................................................359
			Input.............................................................................................359
			Shutdown..........................................................................................359
		9.3.2 Procedure if permissible wind speeds are exceeded...............................................360
		9.3.3 Instructions for turning loads over.............................................................360
	9.4 Maintenance...........................................................................................361
		9.4.3 Description of maintenance work.................................................................362
10 Turning loads over.........................................................................................363
	Prerequisites.............................................................................................363
	10.1 Setting the RCL......................................................................................364
		Entering the reeving..................................................................................364
		Switching over to the auxiliary hoist.................................................................364
	10.2 Turning a load over..................................................................................365
11 Driving with a rigged crane................................................................................367
	11.1 Safety instructions..................................................................................367
	11.2 Route................................................................................................368
	11.3 Permissible rigging modes and axle loads.............................................................369
		Information about the tables..........................................................................369
		11.3.1 Swing-away lattice.............................................................................370
			Swing-away lattice 1.7 + 9.4m....................................................................370
			Swing-away lattice 1.7 + 15.9m...................................................................372
		11.3.2 Boom extension.................................................................................374
			Boom extension 9.7+ 9.4m.........................................................................374
			Boom extension 9.7+ 15.9m........................................................................376
		11.3.3 Heavy load lattice extension (SLS).............................................................378
			Heavy load lattice extension 0.46m + 1.46 m......................................................378
		11.3.4 Heavy load lattice extension (ISS).............................................................380
			Heavy load lattice extension 1.7m + 1.6m .....................................................380
			Heavy load lattice extension 9.7m + 1.6m......................................................382
		11.3.5 Auxiliary single-sheave boom top...............................................................384
	11.4 Before driving.......................................................................................385
	11.5 Whilst driving.......................................................................................385
	11.6 After driving........................................................................................385
12 Index......................................................................................................387
	A.........................................................................................................389
	B.........................................................................................................389
	D.........................................................................................................390
	H.........................................................................................................390
	I.........................................................................................................391
	L.........................................................................................................392
	M.........................................................................................................392
	O.........................................................................................................392
	P.........................................................................................................392
	R.........................................................................................................392
	S.........................................................................................................392
	T.........................................................................................................393

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