Grove Crane GMK 6300 Lattice Extension Operating Manual SN 3112446 – PDF DOWNLOAD

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Grove Crane GMK 6300 Lattice Extension Operating Manual SN 3112446 – PDF DOWNLOAD

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Grove Crane GMK 6300 Lattice Extension Operating Manual SN 3112446 – PDF DOWNLOAD

Language : English
Pages : 346
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Grove Crane GMK 6300 Lattice Extension Operating Manual SN 3112446 – PDF DOWNLOAD

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TABLE OF CONTENTS:

Grove Crane GMK 6300 Lattice Extension Operating Manual SN 3112446 – PDF DOWNLOAD

1 Important information......................................................................................  7
	1.1 About this operating manual..........................................................................  7
		Validity of this operating manual....................................................................  7
		Prerequisites for assembly and operation.............................................................  7
		Safety instructions.................................................................................  7
		References to other operating manuals................................................................  7
		Alternative representations.........................................................................  8
	1.2 Basic safety instructions............................................................................  9
		1.2.1 Warnings and symbols...........................................................................  9
	1.3 Intended use......................................................................................... 10
	1.4 Organisational measures.............................................................................. 12
	1.5 Personnel qualifications............................................................................. 14
	1.6 Safety instructions for working with the truck crane................................................. 15
2 Transport dimensions, weights and allocation of the lattice extension sections............................. 19
	2.1 Transport dimensions and weights in metric units..................................................... 19
		2.1.1 Telescopic swing-away lattice extension........................................................ 19
		2.1.2 Auxiliary single-sheave boom top............................................................... 19
		2.1.3 Boom extension................................................................................. 20
		2.1.4 Luffing jib.................................................................................... 20
		2.1.5 Heavy load lattice extension................................................................... 21
	2.2 Assignment of the parts to lattice extensions........................................................ 23
3 Telescopic swing-away lattice extension.................................................................... 27
	3.1 Supplement to the operation of the GMK6300 with the telescopic swing-away lattice extension ........ 27
		3.1.1 Changed prerequisite for telescoping........................................................... 27
		3.1.2 Instructions for driving with the telescopic swing-away lattice extension mounted sideways..... 28
	3.2 Additional operating and display elements in the driver's cab........................................ 29
		3.2.1 Location of the additional operating and display elements...................................... 30
		3.2.2 The functions of the additional operating and display elements................................. 31
	3.3 Additional operating and display elements in the crane cab........................................... 33
		3.3.1 Location of the additional operating and display elements...................................... 33
		3.3.2 Function of the additional operating and display elements...................................... 34
	3.4 Operating elements on the telescopic swing-away lattice extension................................... 35
		3.4.1 Mobile switch unit............................................................................. 35
	3.5 Components and identification........................................................................ 37
		Components........................................................................................... 37
		Identification....................................................................................... 37
		Serial numbers on telescopic swing- away lattice extension........................................... 38
		Serial number on adapter unit........................................................................ 38
	3.6 Assembly of the lattice extensions................................................................... 39
	3.7 Slinging points...................................................................................... 41
	3.8 Checklists for rigging work.......................................................................... 43
		3.8.1 Overview of the required rigging work.......................................................... 43
		3.8.2 CHECKLIST: Mounting the telescopic swing-away lattice extension............................... 44
		3.8.3 CHECKLIST: Removing the telescopic swing-away lattice extension............................... 45
		3.8.4 CHECKLIST: Rigging the telescopic swing-away lattice extension................................ 46
		3.8.5 CHECKLIST: Unrigging the telescopic swing-away lattice extension.............................. 51
	3.9 Description of the rigging work...................................................................... 57
		3.9.1 Preparing the truck crane for rigging.......................................................... 57
			Prerequisites for rigging........................................................................ 57
			Prerequisites for unrigging...................................................................... 57
		3.9.2 Mounting/removing the adapter unit............................................................. 58
		3.9.3 Checking driving/working with the main boom rigging modes...................................... 59
			Rigging modes with lattice extension folded at the side.......................................... 61
		3.9.4 Connections and positions with the lattice extension folded at the side........................ 62
			Positions in the rear area....................................................................... 63
			Connections in the middle area................................................................... 64
			Connections in the front area.................................................................... 66
		3.9.5 Pin connection to swing the lattice extension.................................................. 67
			Creating a slewing connection.................................................................... 67
			Releasing a slewing connection................................................................... 68
		3.9.6 Swivelling the lattice extension when rigging.................................................. 69
			Requirements for swivelling...................................................................... 69
			When rigging..................................................................................... 69
			When unrigging................................................................................... 69
		3.9.7 Pin connections for working in lattice extension mode.......................................... 70
			Align the lower bearing points................................................................... 71
		3.9.8 Establishing/disconnecting the hydraulic connections........................................... 72
		3.9.9 Electrical connection for rigging work......................................................... 73
		3.9.10 Telescoping the lattice extension............................................................. 74
			Inserting/releasing mechanical safety device..................................................... 74
			Telescoping the lattice extension................................................................ 75
		3.9.11 Adjusting the angle on the lattice extension.................................................. 76
			Attaching the lattice extension to the hoist rope............................................... 76
			Setting the angle................................................................................ 77
			Required pin connections for the angle.......................................................... 78
		3.9.12 Folding the deflection sheave out/in on the foot section...................................... 79
		3.9.13 Placing and reeving the hoist rope............................................................ 80
			Positioning the hoist rope....................................................................... 80
			Reeving the hoist rope........................................................................... 81
		3.9.14 Lifting limit switch on the lattice extension................................................. 82
			Changing over the lifting limit switch........................................................... 82
			Connecting the lifting limit switch.............................................................. 83
		3.9.15 Anemometer on the lattice extension........................................................... 84
			Changing over the anemometer..................................................................... 84
		3.9.16 Transporting the lattice extension............................................................ 85
			On a separate vehicle............................................................................ 85
			Folded at the side............................................................................... 85
	3.10 Working with the lattice extension.................................................................. 86
		Working movements.................................................................................... 86
		RCL shutdown......................................................................................... 86
		Procedure if the permissible wind speed is exceeded.................................................. 86
		3.10.1 Raising and setting down the main boom with rigged lattice extension.......................... 87
			Raising.......................................................................................... 87
			Setting down..................................................................................... 87
		3.10.2 Telescoping with rigged lattice extension..................................................... 88
		3.10.3 Swinging the lattice extension onto the run-up rail........................................... 89
			Swinging outside the crane cab................................................................... 89
			Swinging from the crane cab...................................................................... 90
	3.11 Turning loads with the lattice extension............................................................ 91
		3.11.1 Preconditions................................................................................. 91
		3.11.2 Setting the RCL............................................................................... 92
			Turning a load................................................................................... 93
	3.12 Driving with rigged crane with a rigged lattice extension.......................................... 95
		3.12.1 Driving path.................................................................................. 95
		3.12.2 Position of the boom.......................................................................... 96
			11 m telescopic swing-away lattice extension..................................................... 97
			19 m telescopic swing-away lattice extension..................................................... 98
		3.12.3 Driving the rigged crane...................................................................... 99
			Lock the superstructure and engage the slewing gear holding brake................................ 99
			Retracting the outriggers........................................................................ 99
			Switching over the suspension locking system..................................................... 99
			Switching on the separate steering...............................................................100
			Driving..........................................................................................100
			Extending the outriggers........................................................................101
	3.13 Malfunctions while working with the telescopic swingaway lattice extension.........................103
		3.13.1 Malfunctions on the telescopic swing-away lattice extension...................................103
	3.14 Maintenance plans...................................................................................105
		3.14.1 Maintenance plan M1: monthly/after 100 oper. hrs.............................................105
		3.14.2 Maintenance plan M3: every 3 months/after 300 oper. hrs......................................105
	3.15 Lubrication chart...................................................................................107
	3.16 Maintenance work....................................................................................109
		3.16.1 Assemblies endangered by cleaning work........................................................109
		3.16.2 Preparing the truck crane for maintenance work................................................110
		3.16.3 Lubricating support rollers...................................................................111
		3.16.4 Lubricating the tow chain and the gear chain..................................................112
			Lubricating the gear chain.......................................................................113
			Lubricating the tow chain........................................................................113
		3.16.5 Tension in the tow chain and gear chain check, if required increase tension...................114
			Checking tow chain tension.......................................................................115
			Checking gear chain tension......................................................................115
			Increasing tow chain tension.....................................................................116
			Increasing gear chain tension....................................................................116
		3.16.6 Lubricating the telescope slide faces.........................................................117
		3.16.7 Adjusting the support roller for the telescopic section.......................................118
4 Auxiliary single-sheave boom top...........................................................................121
	4.1 Slinging point.......................................................................................121
	4.2 Description of the rigging work......................................................................123
		4.2.1 Installing/removing auxiliary single-sheave boom top...........................................123
			Installation.....................................................................................123
			Removal..........................................................................................124
		4.2.2 Rigging the auxiliary single-sheave boom top...................................................125
			Rigging in transport position....................................................................125
			Rigging in working position......................................................................125
	4.3 Reeving the hoist rope...............................................................................127
		Positioning the hoist rope...........................................................................127
		Possible reeving methods on the auxiliary single- sheave boom top....................................127
	4.4 Connecting the lifting limit switch and anemometer...................................................129
		Connecting the lifting limit switch..................................................................129
		Connecting the anemometer...........................................................................129
	4.5 Turning loads with the auxiliary single-sheave boom top..............................................131
		Preconditions........................................................................................131
		Setting the RCL......................................................................................132
		Turning a load.......................................................................................133
5 Boom extension.............................................................................................137
	5.1 Components and identification........................................................................137
		Components...........................................................................................137
		Identification.......................................................................................137
		Foot section.........................................................................................138
		Intermediate sections...............................................................................138
		Head.................................................................................................139
		Angle piece..........................................................................................139
	5.2 Possible combinations................................................................................141
	5.3 Slinging points......................................................................................143
	5.4 Rigging the boom extension...........................................................................145
		5.4.1 CHECKLIST: Rigging the boom extension..........................................................145
		5.4.2 CHECKLIST: Unrigging the boom extension........................................................148
	5.5 Description of the rigging work......................................................................151
		5.5.1 Truck crane rigging mode during installation of the boom extension.............................151
		5.5.2 Handling the pins..............................................................................152
		5.5.3 Installing/removing the foot section...........................................................153
			Installation.....................................................................................153
			Removal..........................................................................................153
		5.5.4 Installing/removing the boom extension sections................................................154
			Checks before installation/removal...............................................................154
			Connecting pins..................................................................................154
			Installing.......................................................................................155
			Removing.........................................................................................155
		5.5.5 Transport pins.................................................................................157
		5.5.6 Angle piece....................................................................................158
			Inclining the angle piece to 25.................................................................159
			Angle section at a3 angle......................................................................159
		5.5.7 Changing over the lifting limit switch and anemometer..........................................160
		5.5.8 Establishing/disconnecting the electrical connection...........................................161
			Connecting cable.................................................................................161
			Establishing aconnection........................................................................162
			Disconnecting theconnection.....................................................................163
		5.5.9 Reeving the hoist rope.........................................................................164
			Possible reeving methods.........................................................................166
	5.6 Driving with rigged crane and rigged boom extension..................................................169
		5.6.1 Driving path...................................................................................169
		5.6.2 Position of the boom...........................................................................170
			19 m boom extension.............................................................................171
			27 m boom extension.............................................................................172
			35 m boom extension.............................................................................173
			43 m boom extension.............................................................................174
			51 m boom extension.............................................................................175
		5.6.3 Driving the rigged crane.......................................................................176
			Lock the superstructure and engage the slewing gear holding brake................................176
			Retracting the outriggers........................................................................176
			Switching over the suspension locking system.....................................................176
			Driving..........................................................................................177
			Extending the outriggers........................................................................177
	5.7 Operation with boom extension........................................................................179
		Crane movements......................................................................................180
		RCL Shutdown.........................................................................................180
		Effect of wind when operating the boom extension.....................................................181
		5.7.1 Telescoping with rigged boom extension.........................................................182
	5.8 Maintenance plans....................................................................................183
		5.8.1 Maintenance plan M1: monthly/after 100 oper. hrs..............................................183
	5.9 Lubrication chart....................................................................................185
	5.10 Maintenance work....................................................................................187
		5.10.1 Lubricating the fall-back guard...............................................................187
		5.10.2 Lubricating connecting pins...................................................................187
6 Luffing jib................................................................................................191
	6.1 Additional operating and display elements in the crane cab...........................................191
		6.1.1 Position of the additional operating and display elements......................................192
		6.1.2 Function of the additional operating and display elements......................................194
	6.2 Components and identification........................................................................197
		Components...........................................................................................197
		Identification.......................................................................................197
		Foot section.........................................................................................198
		Intermediate sections and guy piece.................................................................198
		Head.................................................................................................199
		Luffing control arm..................................................................................199
	6.3 Possible combinations................................................................................201
	6.4 Slinging points......................................................................................203
	6.5 Rigging the luffing jib..............................................................................205
		6.5.1 CHECKLIST: Rigging luffing jib.................................................................205
		6.5.2 CHECKLIST: Removing the luffing jib............................................................210
	6.6 Description of the rigging work......................................................................215
		6.6.1 Rigging mode of the truck crane when mounting the luffing jib..................................215
		6.6.2 Installing/removing the luffing control arm....................................................216
			Installing luffing control arm...................................................................216
			Removal..........................................................................................217
		6.6.3 Rigging/unrigging fall-back guard strut........................................................219
			When rigging.....................................................................................219
			When unrigging...................................................................................220
		6.6.4 Handling the pins..............................................................................221
		6.6.5 Installing/removing the foot section...........................................................222
			Installation.....................................................................................222
			Removal..........................................................................................222
		6.6.6 Raising/setting down the luffing control arm...................................................223
			Raising the luffing jib..........................................................................223
			Setting down the luffing control arm.............................................................224
			Raising/folding in the railing...................................................................224
		6.6.7 Preparing the upper hook block for rigging.....................................................225
			Before mounting the foot section.................................................................225
			After mounting the foot section..................................................................225
		6.6.8 Fasten the upper hook block on the luffing control arm.........................................226
		6.6.9 Removing the upper hook block from the luffing control arm.....................................228
		6.6.10 Installing/removing boom sections and rear pendant links......................................230
			Connecting pins..................................................................................230
			Installing.......................................................................................230
			Removing.........................................................................................232
			Rear pendant link transport protection...........................................................234
		6.6.11 Removing/inserting the transport pins.........................................................236
			Removing the transport pins......................................................................236
			Inserting transport pins........................................................................237
		6.6.12 Moving the lifting limit switch and anemometer................................................238
			Changing over the anemometer.....................................................................238
			Connecting the lifting limit switch and anemometer...............................................238
			Locking the lifting limit switch.................................................................239
			Releasing locking................................................................................240
		6.6.13 Establishing/disconnecting the electrical connection..........................................240
			RCL connecting cable.............................................................................240
			Establishing aconnection........................................................................241
			Disconnecting the connection.....................................................................242
		6.6.14 Reeving the hoist rope........................................................................243
			Possible reeving methods.........................................................................245
		6.6.15 Telescoping with the luffing jib..............................................................247
			Telescoping when using the rigged 21m luffing jib...............................................250
		6.6.16 Derricking luffing jib when rigging...........................................................251
		6.6.17 Derricking main boom with installed luffing jib...............................................253
			Derricking between –1.5 to 82..................................................................253
			Derricking between 70and82...................................................................253
		6.6.18 Putting the luffing jib into working position.................................................254
			Raise the luffing jib............................................................................254
			Telescoping to fixed length......................................................................257
			Entering working position........................................................................257
		6.6.19 Preparing the luffing jib for unrigging.......................................................258
		6.6.20 Checking the shutdown angles..................................................................262
			Initial position.................................................................................262
			Checking the shutdown angles....................................................................263
	6.7 Operating with the luffing jib.......................................................................267
		6.7.1 Maximum permitted slewing speed................................................................268
		6.7.2 Crane movements................................................................................269
		6.7.3 Working range and shutdowns....................................................................270
		6.7.4 RCL shutdown...................................................................................271
			The effect of wind when operating with the luffing jib...........................................272
		6.7.5 Malfunctions when working with theluffing jib.................................................273
	6.8 Driving with rigged crane and rigged luffing jib.....................................................275
		6.8.1 Driving path...................................................................................275
		6.8.2 Position of the boom...........................................................................276
			21 m luffing jib.................................................................................277
			29 m luffing jib.................................................................................278
			37 m luffing jib.................................................................................279
			45 m luffing jib.................................................................................280
			53 m luffing jib.................................................................................281
			61 m luffing jib.................................................................................282
		6.8.3 Driving the rigged crane.......................................................................283
			Lock the superstructure and engage the slewing gear holding brake................................283
			Retracting the outriggers........................................................................283
			Switching over the suspension locking system.....................................................283
			Extending the outriggers........................................................................284
	6.9 Maintenance plans....................................................................................285
		6.9.1 Maintenance plan M1: monthly/after 100 oper. hrs..............................................285
		6.9.2 Maintenance plan M6: every six monthly/after 500 oper. hrs....................................285
	6.10 Lubrication chart...................................................................................287
	6.11 Maintenance work....................................................................................289
		6.11.1 Lubricating the fall-back guard...............................................................289
		6.11.2 Lubricating connecting pins...................................................................289
		6.11.3 Checking the nitrogen and oil pressure in the fall-back guard strut...........................290
			Test connections.................................................................................290
			Nitrogen pressure................................................................................291
			Oil pressure.....................................................................................293
7 Heavy load lattice extension...............................................................................297
	7.1 Components and identification........................................................................297
	7.2 Possible combinations................................................................................299
	7.3 Slinging points......................................................................................301
	7.4 Rigging the heavy load lattice extension.............................................................303
		7.4.1 CHECKLIST: Rigging the heavy load lattice extension............................................303
		7.4.2 CHECKLIST: Unrigging the heavy load lattice extension..........................................305
	7.5 Description of the rigging work......................................................................307
		7.5.1 Truck crane rigging mode during installation of the heavy load lattice extension...............307
		7.5.2 Handling the pins..............................................................................308
		7.5.3 Installing/removing heavy load lattice extension sections......................................308
			Connecting pins..................................................................................308
			Installing.......................................................................................309
			Removing.........................................................................................310
		7.5.4 Angle piece....................................................................................311
			Inclining the angle piece to 40.................................................................312
			Angle section at a18 angle.....................................................................312
		7.5.5 Moving the lifting limit switch and anemometer.................................................313
			Connecting the lifting limit switch and anemometer...............................................314
		7.5.6 Establishing/disconnecting the electrical connection...........................................314
			Connecting cable.................................................................................314
			Establishing connection.........................................................................315
			Disconnecting the connection.....................................................................316
		7.5.7 Reeving the hoist rope.........................................................................317
			Possible reeving methods on the heavy load lattice extension.....................................319
	7.6 Operating the heavy load lattice extension...........................................................321
		Telescoping with rigged heavy load lattice extension.................................................321
		7.6.1 Crane movements................................................................................322
			RCL shutdown.....................................................................................322
			Effect of wind when operating the heavy load lattice extension..................................323
	7.7 Turning loads with the heavy load lattice extension..................................................325
		Preconditions........................................................................................325
		Setting the RCL......................................................................................326
		Turning a load.......................................................................................327
	7.8 Driving with a rigged crane and rigged heavy load lattice extension.................................329
		7.8.1 Driving path...................................................................................329
		7.8.2 Position of the boom...........................................................................330
			Heavy load lattice extension 3.5m...............................................................331
			Heavy load lattice extension 7.0m...............................................................332
		7.8.3 Driving the rigged crane.......................................................................333
			Lock the superstructure and engage the slewing gear holding brake................................333
			Retracting the outriggers........................................................................333
			Switching over the suspension locking system.....................................................333
			Switching on the separate steering...............................................................334
			Driving..........................................................................................334
			Extending the outriggers........................................................................335
8 Index......................................................................................................339
	A........................................................................................................341
	B........................................................................................................341
	C........................................................................................................341
	D........................................................................................................341
	E........................................................................................................341
	F........................................................................................................342
	H........................................................................................................342
	I........................................................................................................342
	L........................................................................................................342
	M........................................................................................................342
	O........................................................................................................343
	P........................................................................................................343
	R........................................................................................................343
	S........................................................................................................343
	T........................................................................................................344
	U........................................................................................................344

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