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Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112975 – PDF DOWNLOAD
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Description
Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112975 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112975 – PDF DOWNLOAD
Language : English
Pages : 398
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112975 – PDF DOWNLOAD
Basic safety instructions:
- In principle, the basic safety instructions apply from the Operating Instruc- tions GMK 6400. The
basic safety instructions for the lattice extensions sup- plied for the truck crane are given
below. - Information regarding the warnings and symbols used; à Operating Instructions GMK 6400.
Intended use:
The GMK 6400 is a state-of-the-art truck crane, designed in accordance with approved safety
regulations. Nevertheless, the operator or third parties can still be endangered and the crane or
other property put at risk while using it.
- In addition to the following specifications, also observe the specifications for intended use in
the Operating Instructions GMK 6400. - The GMK 6400 may only be operated with parts of equipment which are permitted by Manitowoc Crane
Group Germany GmbH and which are labelled with the serial number of the GMK 6400. - Observe the inspection and maintenance requirements for the lattice exten- sion according to the
Maintenance chapter.
Only use the rigging winch (special equipment) to do the following:
– To pull the rope of the hoisting gear to the head when rigging the boom extension and the
luffing jib
– To pull the rope of the hoisting gear over the luffing control arm to the
upper hook block when rigging the luffing jib
TABLE OF CONTENTS:
Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112975 – PDF DOWNLOAD
Additional page: Slinging points on the auxiliary single-sheave boom top.......................... 3 Additional page: Modified rigging winch........................................................... 5 Validity...................................................................................... 5 Modifications............................................................................. 5 Rope guide.................................................................................... 6 Rope guide for the mounting sites......................................................... 6 Additional support roller............................................................. 6 Positioning the rigging rope on the support roller/taking it off the support roller....... 7 Setting the support roller upright/laying it down......................................... 7 Additional page: Operating with the luffing jib .................................................. 9 Correction sheet: Electrical connection head/foot section......................................... 11 1 Overview........................................................................................ 21 1.1 Accidents................................................................................. 21 1.2 Warranty.................................................................................. 21 1.3 Terms used................................................................................ 22 1.3.1 For the boom extension.............................................................. 22 1.3.2 For the luffing jib................................................................. 24 1.3.3 For the heavy load lattice extension................................................ 26 1.3.4 For the auxiliary single-sheave boom top............................................ 27 1.3.5 For operation of the rigging winch.................................................. 28 1.3.6 On the main boom.................................................................... 29 1.4 Notes about the lattice extension operating manual........................................ 31 1.4.1 What do the symbols used mean?...................................................... 31 1.4.2 Definitions of direction information................................................ 31 Basic rule............................................................................ 31 Switches and buttons................................................................. 32 General information on the operating elements......................................... 32 General rules for buttons and symbols................................................ 32 1.4.3 How are the operating instructions structured?...................................... 33 1.4.4 How do I find the information I need?............................................... 34 1.5 Conversion table for US measurements...................................................... 35 2 Basic safety instructions....................................................................... 39 2.1 Intended use.............................................................................. 39 2.2 Improper use.............................................................................. 40 2.3 Organisational measures................................................................... 40 2.4 Personnel qualifications.................................................................. 41 Requirements.............................................................................. 41 Training courses.......................................................................... 41 2.5 Safety instructions for working with the lattice extension............................... 42 2.6 Information on transporting persons....................................................... 43 3 For operations planning......................................................................... 47 3.1 Boom extension, luffing jib and heavy load lattice extension.............................. 47 3.1.1 Notes on assembly................................................................... 47 3.1.2 Assembly of the boom extension 3 inclined.......................................... 48 3.1.3 Assembly of the boom extension 25 inclined......................................... 54 3.1.4 Assembly of the luffing jib without inclination..................................... 58 3.1.5 Assembly of the luffing jib with inclination........................................ 62 3.1.6 Assembly of the heavy load lattice extension........................................ 64 3.1.7 Transport dimensions and weights.................................................... 65 Foot section in different combinations.............................................. 68 Intermediate sections pushed into each other......................................... 70 3.1.8 Identification...................................................................... 71 3.1.9 Slinging points..................................................................... 75 Slinging points on the foot section................................................... 77 3.1.10 Transport.......................................................................... 79 Applicable for all sections........................................................... 79 For the foot section/luffing control arm............................................. 79 For the head.......................................................................... 80 3.2 Auxiliary single-sheave boom top.......................................................... 81 3.2.1 Assembly............................................................................ 81 3.2.2 Identification and slinging point................................................... 81 3.2.3 Transport dimensions and weight..................................................... 82 4 Additional operating and display elements....................................................... 85 4.1 Overview of the operating elements........................................................ 85 4.1.1 On the crane control display........................................................ 85 Main menu............................................................................. 85 Luffing jib submenu.................................................................. 86 Power unit speeds submenu............................................................. 86 4.1.2 On the RCL display.................................................................. 87 Submenu for entering rigging mode..................................................... 87 Submenu for RCL monitoring............................................................ 87 4.1.3 On the hand-held control............................................................ 88 4.2 Brief description of the operating elements............................................... 89 4.2.1 On the crane control display........................................................ 89 In the power unit speed submenu....................................................... 89 In the Luffing jib submenu............................................................ 89 4.2.2 On the RCL display.................................................................. 97 Entering rigging mode in submenu...................................................... 97 In the RCL monitoring submenu......................................................... 98 4.2.3 On the hand-held control............................................................ 99 Pre-selection......................................................................... 99 Movements of the rigging winch........................................................100 5 Boom extension..................................................................................103 5.1 Checklists for rigging work...............................................................103 5.1.1 CHECKLIST: Rigging the boom extension...............................................103 5.1.2 CHECKLIST: Unrigging the boom extension.............................................109 5.2 Description of the rigging work...........................................................113 5.2.1 Pulling apart/pushing together intermediate sections................................113 Folding up/folding out holders........................................................113 Installing/removing the rear pendant links...........................................113 Pulling apart intermediate sections...................................................114 Pushing together intermediate sections...............................................115 5.2.2 Checking the bracing arms...........................................................116 5.2.3 Rigging mode of the truck crane at installation and removal.........................117 5.2.4 Establishing/disconnecting the connections for the hydraulic lock...................118 Making the connections...............................................................118 Breaking the connections.............................................................119 5.2.5 Securing/releasing locks............................................................120 5.2.6 Locking the foot section/releasing the lock.........................................121 Prerequisites.........................................................................121 Locking the foot section..............................................................121 Releasing the lock....................................................................122 5.2.7 Handling the pins...................................................................123 5.2.8 Installing/removing boom extension sections.........................................124 Before the installation...............................................................124 Installing............................................................................124 Removing..............................................................................125 5.2.9 Blocking the joint on the foot section..............................................126 5.2.10 Removing/installing the deflection sheave on the angle piece.......................127 5.2.11 Replacing deflection sheaves on the angle piece....................................128 5.2.12 Folding deflection sheaves up/down.................................................129 On the angle piece....................................................................129 On the foot section..................................................................130 5.2.13 Setting the angle position of the boom extension...................................131 5.2.14 Installing/removing the lifting limit switch.......................................133 Installing lifting limit switch.......................................................133 Removing the lifting limit switch....................................................134 5.2.15 Anemometer and air traffic control light...........................................135 Installing............................................................................135 Removing..............................................................................135 5.2.16 Electrical connection foot section/main boom.......................................136 Establishing..........................................................................136 Disconnecting.........................................................................136 5.2.17 Electric connection head/foot section..............................................137 Connecting cable......................................................................137 Establishing..........................................................................137 Disconnecting.........................................................................138 5.2.18 Placing and reeving the hoist rope.................................................140 Possible reeving methods..............................................................142 5.3 Operation with boom extension.............................................................145 5.3.1 Operating the RCL...................................................................146 Entering the RCL code.................................................................146 Enter components......................................................................146 Accepting the rigging mode...........................................................148 Checks and displays in the Monitoring submenu.........................................148 5.3.2 RCL shutdown........................................................................150 5.3.3 Crane movements.....................................................................150 5.3.4 Telescoping with rigged boom extension..............................................151 5.3.5 Checks when operating with the boom extension.......................................152 Horizontal alignment.................................................................152 Checking the wind speed...............................................................152 6 Luffing jib.....................................................................................157 6.1 Checklists for rigging work...............................................................157 6.1.1 CHECKLIST: Rigging the luffing jib..................................................157 6.1.2 CHECKLIST: Unrigging the luffing jib................................................165 6.2 Description of the rigging work...........................................................171 6.2.1 Ladder and railing..................................................................171 When rigging..........................................................................171 When unrigging........................................................................172 Railing on the luffing control arm....................................................174 6.2.2 Pulling apart/pushing together intermediate sections................................175 6.2.3 Checking the bracing arms...........................................................175 6.2.4 Rigging mode of the truck crane at installation and removal.........................175 6.2.5 Installing/removing the luffing control arm.........................................176 Installation..........................................................................176 Removal...............................................................................179 6.2.6 Raising/setting down the luffing control arm........................................182 Raising the luffing control arm.......................................................182 Setting down the luffing control arm..................................................182 6.2.7 Hand-held control...................................................................183 Moving the hoists.....................................................................183 Moving the rigging winch.............................................................183 6.2.8 Separating/connecting catcher 2 and raising cylinder................................184 Setting down/ raising catcher 2.......................................................184 Separating catcher 2 and the raising cylinder.........................................185 Connecting catcher 2 and raising cylinder............................................185 6.2.9 Reeving the auxiliary hoist rope to the upper hook block............................186 6.2.10 Preparing the upper hook block for rigging.........................................188 Before mounting the foot section......................................................188 After mounting the foot section.......................................................189 6.2.11 Fastening the upper hook block on the luffing control arm..........................189 Releasing the safety device on the upper hook block...................................189 Pulling the upper hook block towards the luffing control arm.........................190 Locking the upper hook block..........................................................191 6.2.12 Releasing the upper hook block from the luffing control arm........................193 Releasing the locking pin.............................................................193 Pulling the upper hook block towards the catcher......................................194 Securing the upper hook block in the catcher..........................................195 Reeling up the hoist rope.............................................................196 6.2.13 Replacing the intermediate sections on the foot section............................197 Prerequisites.........................................................................197 When rigging..........................................................................198 When unrigging........................................................................199 6.2.14 Installing/removing sections of the luffing jib and rear pendant links.............200 Before the installation..............................................................200 Installing............................................................................200 Removing..............................................................................202 Rear pendant link transport protection...............................................204 6.2.15 Hinge lock in the foot section.....................................................205 Releasing the hinge lock..............................................................205 Locking the hinge.....................................................................207 6.2.16 Setting the angle of the luffing jib...............................................209 6.2.17 Placing and reeving the hoist rope.................................................211 Possible reeving methods..............................................................212 6.2.18 Opening the luffing jib submenu....................................................213 6.2.19 Telescoping with the luffing jib...................................................214 Prerequisites.........................................................................214 Telescoping with teleautomation.......................................................215 Telescoping with semi-automatic.......................................................217 6.2.20 Derricking luffing jib when rigging................................................219 Prerequisites.........................................................................219 6.2.21 Derricking main boom with installed luffing jib....................................221 Derricking between –1.5 to 82 .......................................................221 Derricking between 80 and 60 ........................................................222 6.2.22 Putting the luffing jib into working position......................................223 Raising the luffing jib...............................................................223 Telescoping to fixed length...........................................................224 Lowering to working position.........................................................225 6.2.23 Preparing the luffing jib for unrigging............................................226 6.3 Operating with the luffing jib............................................................229 6.3.1 Operating the RCL...................................................................230 Entering the RCL code for the luffing jib.............................................230 Entering components for the luffing jib..............................................230 Accepting the rigging mode...........................................................232 Checks and displays in the Monitoring submenu.......................................233 6.3.2 RCL shutdown........................................................................235 6.3.3 Crane movements.....................................................................236 Controlling...........................................................................236 Derricking the main boom..............................................................236 Maximum power unit speeds.............................................................236 Shutdowns.............................................................................236 6.3.4 Working range and shutdowns.........................................................237 6.3.5 Checks when operating with the luffing jib..........................................239 Horizontal alignment.................................................................239 Checking the wind speed...............................................................239 7 Heavy load lattice extension....................................................................243 7.1 Rigging the heavy load lattice extension..................................................243 7.1.1 CHECKLIST: Rigging the heavy load lattice extension.................................243 7.1.2 CHECKLIST: Unrigging the heavy load lattice extension...............................247 7.2 Description of the rigging work...........................................................251 7.2.1 Truck crane rigging mode during installation of the heavy load lattice extension....251 7.2.2 Establishing/disconnecting the connections for the hydraulic lock...................252 Making the connections...............................................................252 Breaking the connections.............................................................253 7.2.3 Securing/releasing locks............................................................254 7.2.4 Handling the pins...................................................................255 7.2.5 Locking the adapter/releasing the pin...............................................256 Prerequisites.........................................................................256 Locking the adapter...................................................................256 Releasing the locking pin.............................................................257 7.2.6 Replacing deflection sheaves on the angle piece.....................................258 7.2.7 Installing/removing head section and angle piece....................................259 Installing............................................................................259 Removing..............................................................................259 7.2.8 Folding deflection sheaves up/down..................................................261 On the angle piece....................................................................261 On the adapter........................................................................262 7.2.9 Setting the angle position of the heavy load lattice extension......................263 7.2.10 Installing/removing the lifting limit switch.......................................265 Installing lifting limit switch.......................................................265 Removing the lifting limit switch....................................................266 7.2.11 Anemometer and air traffic control light...........................................267 Installing............................................................................267 Removing..............................................................................267 7.2.12 Establishing/disconnecting the electrical connection...............................268 Establishing aconnection.............................................................268 Disconnecting.........................................................................269 7.2.13 Placing and reeving hoist rope.....................................................270 Possible reeving methods..............................................................271 7.3 Operating the heavy load lattice extension................................................273 7.3.1 Operating the RCL...................................................................273 Entering the RCL code for the heavy load lattice extension...........................273 Entering components for the heavy load lattice extension..............................273 Accepting the rigging mode...........................................................275 Checks and displays in the Monitoring submenu.......................................276 7.3.2 RCL shutdown........................................................................277 7.3.3 Crane movements.....................................................................277 7.3.4 Telescoping with rigged heavy load lattice extension................................278 7.3.5 Checks when operating with the heavy load lattice extension.........................279 Horizontal alignment.................................................................279 Checking the wind speed...............................................................279 7.3.6 Notes on two-hook operation.........................................................280 8 Auxiliary single-sheave boom top................................................................283 8.1 Installing/removing.......................................................................283 8.1.1 Installing/removing the auxiliary single-sheave boom top............................283 Installing............................................................................283 Removing..............................................................................284 8.2 Rigging the auxiliary single-sheave boom top..............................................285 8.2.1 Rigging in working position/transport position......................................285 8.2.2 Attaching and removing the hoist rope...............................................286 Possible reeving methods..............................................................287 8.2.3 Lifting limit switch and anemometer.................................................288 Lifting limit switch..................................................................288 Installing and removing...............................................................289 8.3 Operation with the auxiliary single-sheave boom top.......................................290 8.3.1 Setting the RCL.....................................................................290 8.3.2 Derricking, telescoping the main boom...............................................290 8.3.3 Notes on RCL shutdown...............................................................291 8.3.4 Procedure if permissible wind speeds are exceeded...................................291 8.3.5 RCL display with the auxiliary single-sheave boom top folded up/rigged..............292 8.3.6 Notes on two-hook operation.........................................................292 9 Turning loads...................................................................................295 9.1 Requirements..............................................................................296 9.2 Setting the RCL to turn loads.............................................................297 Entering the reevings....................................................................297 Setting the RCL to the auxiliary hoist....................................................297 9.3 Turning a load............................................................................299 10 Rigging winch (additional equipment)...........................................................305 10.1 Overview.................................................................................305 Operating principle and accessories.......................................................305 10.2 Hand-held control........................................................................306 10.3 Pulling the hoist rope to the head.......................................................307 Requirements..............................................................................307 Remarks...................................................................................307 Rigging work on the sheaves for operating the rigging winch...............................308 Reeling off the rigging rope..............................................................309 Positioning the rigging rope..............................................................310 Connecting the rigging rope and the hoist rope............................................310 Unreeling the hoist rope..................................................................311 Separating the rigging rope and the hoist rope............................................312 Rolling the rigging rope onto the drum....................................................312 Rigging work on the sheaves for crane operation...........................................314 10.4 Pulling the hoist rope to the upper hook block...........................................315 Requirements..............................................................................315 Rigging work on the sheaves for operating the rigging winch...............................316 Reeling off the rigging rope..............................................................317 Positioning the rigging rope..............................................................318 Connecting the rigging rope and the main hoist rope.......................................319 Reeling off the main hoist rope...........................................................319 Separating the rigging rope and the main hoist rope.......................................319 Rolling the rigging rope onto the drum....................................................320 10.5 Rigging work.............................................................................321 10.5.1 For operation of the rigging winch.................................................321 Releasing the winch lock..............................................................321 Locking the winch.....................................................................321 Loosening the rigging rope at the rope attachment point...............................322 Fastening the rigging rope at the rope attachment point...............................323 Installing the rigging winch..........................................................323 Removing the rigging winch............................................................325 10.5.2 Connecting/disconnecting the electrical connection.................................326 Establishing..........................................................................326 Disconnecting.........................................................................326 10.5.3 Establishing/disconnecting the hydraulic connection................................327 Establishing..........................................................................327 Disconnecting.........................................................................327 10.5.4 Rigging on the foot section........................................................328 For operation of the rigging winch....................................................328 For crane operation...................................................................329 10.5.5 Guide sheaves......................................................................330 Inserting or removing the rigging rope................................................330 10.5.6 On the angle piece.................................................................331 For operation of the rigging winch....................................................331 For crane operation...................................................................331 10.5.7 On the head........................................................................332 For operation of the rigging winch....................................................332 For crane operation...................................................................332 10.5.8 Rope connector.....................................................................333 Establishing the connection...........................................................333 Undoing the connection................................................................335 11 Driving with rigged truck crane................................................................339 11.1 Driving distance.........................................................................340 11.2 Permissible rigging modes and axle loads.................................................340 11.2.1 Rigging modes with boom extension..................................................340 11.2.2 Rigging modes with luffing jib.....................................................341 11.2.3 Rigging modes with the heavy load lattice extension................................344 11.2.4 Rigging modes with the auxiliary single-sheave boom top............................344 11.3 Before driving the rigged truck crane....................................................345 11.4 Driving the rigged truck crane...........................................................345 Driving from the driver's cab.............................................................345 While driving.............................................................................345 11.5 Tables with boom positions and axle loads................................................347 Information about the tables..............................................................347 11.5.1 Boom extension with 3 angle.......................................................348 11.5.2 Boom extension with 25 angle......................................................348 11.5.3 Luffing jib........................................................................348 11.5.4 Heavy load lattice extension.......................................................348 11.5.5 Auxiliary single-sheave boom top...................................................348 12 Malfunctions...................................................................................351 12.1 Notes on troubleshooting.................................................................351 General information......................................................................351 What to do in theevent of malfunctions..................................................351 Fuses.....................................................................................351 ECOS malfunctions........................................................................351 RCL malfunctions..........................................................................351 12.2 Troubleshooting and remedies.............................................................353 12.2.1 Boom extension and heavy load lattice extension....................................353 12.2.2 Luffing jib........................................................................353 12.3 RCL malfunctions.........................................................................357 12.3.1 Table of lattice extension error codes.............................................358 12.3.2 Checking RCL supply lines and connections..........................................359 On the lattice extension..............................................................360 13 Maintenance....................................................................................363 13.1 Cleaning work............................................................................364 Overview of subassemblies easily damaged when cleaning....................................364 13.2 Maintenance plans........................................................................367 13.2.1 Maintenance plan M 1...............................................................367 13.2.2 Maintenance plan M 3...............................................................367 13.2.3 Maintenance plan Y 2...............................................................368 13.2.4 Maintenance plan Y 5...............................................................368 13.2.5 Maintenance plan Y 10..............................................................368 13.3 Boom extension and luffing jib...........................................................369 13.3.1 Lubricating the connecting and socket pins.........................................369 Grease, tools.........................................................................369 Prerequisites.........................................................................369 Checking..............................................................................369 Lubricating...........................................................................370 13.3.2 Lubricating the lower joint........................................................371 Grease, spare parts, tools............................................................371 Prerequisites.........................................................................371 Lubrication...........................................................................371 13.3.3 Checking the sheaves...............................................................372 13.3.4 Checking the nitrogen pressure and oil pressure in the fall-back guard strut.......373 Spare parts and tools.................................................................373 Prerequisites.........................................................................373 Test connections......................................................................374 Nitrogen pressure.....................................................................374 Oil pressure..........................................................................378 13.3.5 Required inspections for the fall-back guard strut.................................380 13.4 Rigging winch (additional equipment).....................................................381 13.4.1 Lubricating the bearings...........................................................381 Grease, spare parts, tools............................................................381 Prerequisites.........................................................................381 Lubricating...........................................................................381 13.4.2 Greasing the driving pinions.......................................................382 Grease, spare parts, tools............................................................382 Prerequisites.........................................................................382 Greasing..............................................................................382 13.4.3 Checking the condition of the rigging rope.........................................383 13.4.4 Changing the rigging rope..........................................................384 Spare parts and tools.................................................................384 Prerequisites.........................................................................384 Removing the old rope.................................................................384 Attaching a new rope..................................................................385 14 Index..........................................................................................389 A.............................................................................................391 B.............................................................................................391 C.............................................................................................391 F.............................................................................................391 H.............................................................................................391 I.............................................................................................392 L.............................................................................................392 M.............................................................................................393 O.............................................................................................393 P.............................................................................................394 R.............................................................................................394 S.............................................................................................395 T.............................................................................................395 W.............................................................................................395 3_113_006_EN_20130903.pdf......................................................................... 0
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