Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112976 – PDF DOWNLOAD
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Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112976 – PDF DOWNLOAD
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Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112976 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112976 – PDF DOWNLOAD
Language : English
Pages : 396
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:
Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112976 – 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
Improper use:
- Manitowoc Crane Group Germany GmbH is not liable for damage resulting from the improper or
unauthorized use of the GMK 6400 truck crane. The user alone bears the risk. - In addition to the following specifications, also observe the information regarding improper use in
the Operating Instructions GMK 6400.
If a rigging winch (additional equipment) is mounted, improper use also includes:
– Pulling the main hoist rope using the rigging winch (additional equip- ment) to the main boom
head when no lattice extension is mounted
– Any type of vertical hoisting of loads using the rigging winch
Organisational measures:
In addition to the following specifications, also observe the organisational measures in the
Operating Instructions GMK 6400 and in the Maintenance Manual.
Make sure the maintenance personnel also have the necessary expertise to operate the crane safely.
Make sure the maintenance personnel have access to the operating manual.
- Only qualified or instructed personnel may carry out work on the truck crane.
- The responsibilities regarding the operation of the crane, rigging, mainte- nance and repair work
must be clearly defined. - Make sure that persons who will work on the truck crane are provided with the required information
prior to commencing work. Instruct your person- nel (e.g. banksmen, slingers, rigging personnel)
accordingly. - Observe all safety instructions and warnings on the truck crane.
- Climb on the foot section only via the ladder provided. Erect the railing. This
gives you a safe access to the foot section.
TABLE OF CONTENTS:
Grove Crane GMK 6400 Lattice Extension Operating Instruction Manual 3112976 – PDF DOWNLOAD
Additional page: Slinging points on the auxiliary single-sheave boom top.......................... 3 Additional pages: 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........................................................................................ 17 1.1 Accidents................................................................................. 17 1.2 Warranty.................................................................................. 17 1.3 Terms used................................................................................ 18 1.3.1 For the boom extension.............................................................. 18 1.3.2 For the luffing jib................................................................. 20 1.3.3 For the heavy load lattice extension................................................ 22 1.3.4 For the auxiliary single-sheave boom top............................................ 23 1.3.5 For operation of the rigging winch.................................................. 24 1.3.6 On the main boom.................................................................... 25 1.4 Notes about the lattice extension operating manual........................................ 27 1.4.1 What do the symbols used mean?...................................................... 27 1.4.2 Definitions of direction information................................................ 27 Basic rule............................................................................ 27 Switches and buttons................................................................. 28 General information on the operating elements......................................... 28 General rules for buttons and symbols................................................ 28 1.4.3 How are the operating instructions structured?...................................... 29 1.4.4 How do I find the information I need?............................................... 30 1.5 Specifications in US standard units of measurement........................................ 31 1.5.1 Boom extension...................................................................... 31 1.5.2 Luffing jib......................................................................... 32 1.5.3 Heavy load lattice extension........................................................ 32 1.6 Conversion table for US measurements...................................................... 33 2 Basic safety instructions....................................................................... 37 2.1 Intended use.............................................................................. 37 2.2 Improper use.............................................................................. 38 2.3 Organisational measures................................................................... 38 2.4 Personnel qualifications.................................................................. 39 Requirements.............................................................................. 39 Training courses.......................................................................... 39 2.5 Safety instructions for working with the lattice extension............................... 40 2.6 Information on transporting persons....................................................... 41 3 For operations planning......................................................................... 45 3.1 Boom extension, luffing jib and heavy load lattice extension.............................. 45 3.1.1 Notes on assembly................................................................... 45 3.1.2 Assembly of the boom extension 3 inclined.......................................... 46 3.1.3 Assembly of the boom extension 25 inclined......................................... 52 3.1.4 Assembly of the luffing jib without inclination..................................... 56 3.1.5 Assembly of the luffing jib with inclination........................................ 60 3.1.6 Assembly of the heavy load lattice extension........................................ 62 3.1.7 Transport dimensions and weights.................................................... 63 Foot section in different combinations.............................................. 66 Intermediate sections pushed into each other......................................... 68 3.1.8 Identification...................................................................... 69 3.1.9 Slinging points..................................................................... 73 Slinging points on the foot section................................................... 75 3.1.10 Transport.......................................................................... 77 Applicable for all sections........................................................... 77 For the foot section/luffing control arm............................................. 77 For the head.......................................................................... 78 3.2 Auxiliary single-sheave boom top.......................................................... 79 3.2.1 Assembly............................................................................ 79 3.2.2 Identification and slinging point................................................... 79 3.2.3 Transport dimensions and weight..................................................... 80 4 Additional operating and display elements....................................................... 83 4.1 Overview of the operating elements........................................................ 83 4.1.1 On the crane control display........................................................ 83 Main menu............................................................................. 83 Luffing jib submenu.................................................................. 84 Power unit speeds submenu............................................................. 84 4.1.2 On the RCL display.................................................................. 85 Submenu for entering rigging mode..................................................... 85 Submenu for RCL monitoring............................................................ 85 4.1.3 On the hand-held control............................................................ 86 4.2 Brief description of the operating elements............................................... 87 4.2.1 On the crane control display........................................................ 87 In the power unit speed submenu....................................................... 87 In the Luffing jib submenu............................................................ 87 4.2.2 On the RCL display.................................................................. 95 Entering rigging mode in submenu...................................................... 95 In the RCL monitoring submenu......................................................... 96 4.2.3 On the hand-held control............................................................ 97 Pre-selection......................................................................... 97 Movements of the rigging winch........................................................ 98 5 Boom extension..................................................................................101 5.1 Checklists for rigging work...............................................................101 5.1.1 CHECKLIST: Rigging the boom extension...............................................101 5.1.2 CHECKLIST: Unrigging the boom extension.............................................107 5.2 Description of the rigging work...........................................................111 5.2.1 Pulling apart/pushing together intermediate sections................................111 Folding up/folding out holders........................................................111 Installing/removing the rear pendant links...........................................111 Pulling apart intermediate sections...................................................112 Pushing together intermediate sections...............................................113 5.2.2 Checking the bracing arms...........................................................114 5.2.3 Rigging mode of the truck crane at installation and removal.........................115 5.2.4 Establishing/disconnecting the connections for the hydraulic lock...................116 Making the connections...............................................................116 Breaking the connections.............................................................117 5.2.5 Securing/releasing locks............................................................118 5.2.6 Locking the foot section/releasing the lock.........................................119 Prerequisites.........................................................................119 Locking the foot section..............................................................119 Releasing the lock....................................................................120 5.2.7 Handling the pins...................................................................121 5.2.8 Installing/removing boom extension sections.........................................122 Before the installation...............................................................122 Installing............................................................................122 Removing..............................................................................123 5.2.9 Blocking the joint on the foot section..............................................124 5.2.10 Removing/installing the deflection sheave on the angle piece.......................125 5.2.11 Replacing deflection sheaves on the angle piece....................................126 5.2.12 Folding deflection sheaves up/down.................................................127 On the angle piece....................................................................127 On the foot section..................................................................128 5.2.13 Setting the angle position of the boom extension...................................129 5.2.14 Installing/removing the lifting limit switch.......................................131 Installing lifting limit switch.......................................................131 Removing the lifting limit switch....................................................132 5.2.15 Anemometer and air traffic control light...........................................133 Installing............................................................................133 Removing..............................................................................133 5.2.16 Electrical connection foot section/main boom.......................................134 Establishing..........................................................................134 Disconnecting.........................................................................134 5.2.17 Electric connection head/foot section..............................................135 Connecting cable......................................................................135 Establishing..........................................................................135 Disconnecting.........................................................................136 5.2.18 Placing and reeving the hoist rope.................................................138 Possible reeving methods..............................................................140 5.3 Operation with boom extension.............................................................143 5.3.1 Operating the RCL...................................................................144 Entering the RCL code.................................................................144 Enter components......................................................................144 Accepting the rigging mode...........................................................146 Checks and displays in the Monitoring submenu.........................................146 5.3.2 RCL shutdown........................................................................148 5.3.3 Crane movements.....................................................................148 5.3.4 Telescoping with rigged boom extension..............................................149 5.3.5 Checks when operating with the boom extension.......................................150 Horizontal alignment.................................................................150 Checking the wind speed...............................................................150 6 Luffing jib.....................................................................................155 6.1 Checklists for rigging work...............................................................155 6.1.1 CHECKLIST: Rigging the luffing jib..................................................155 6.1.2 CHECKLIST: Unrigging the luffing jib................................................163 6.2 Description of the rigging work...........................................................169 6.2.1 Ladder and railing..................................................................169 When rigging..........................................................................169 When unrigging........................................................................170 Railing on the luffing control arm....................................................172 6.2.2 Pulling apart/pushing together intermediate sections................................173 6.2.3 Checking the bracing arms...........................................................173 6.2.4 Rigging mode of the truck crane at installation and removal.........................173 6.2.5 Installing/removing the luffing control arm.........................................174 Installation..........................................................................174 Removal...............................................................................177 6.2.6 Raising/setting down the luffing control arm........................................180 Raising the luffing control arm.......................................................180 Setting down the luffing control arm..................................................180 6.2.7 Hand-held control...................................................................181 Moving the hoists.....................................................................181 Moving the rigging winch.............................................................181 6.2.8 Separating/connecting catcher 2 and raising cylinder................................182 Setting down/ raising catcher 2.......................................................182 Separating catcher 2 and the raising cylinder.........................................183 Connecting catcher 2 and raising cylinder............................................183 6.2.9 Reeving the auxiliary hoist rope to the upper hook block............................184 6.2.10 Preparing the upper hook block for rigging.........................................186 Before mounting the foot section......................................................186 After mounting the foot section.......................................................187 6.2.11 Fastening the upper hook block on the luffing control arm..........................187 Releasing the safety device on the upper hook block...................................187 Pulling the upper hook block towards the luffing control arm.........................188 Locking the upper hook block..........................................................189 6.2.12 Releasing the upper hook block from the luffing control arm........................191 Releasing the locking pin.............................................................191 Pulling the upper hook block towards the catcher......................................192 Securing the upper hook block in the catcher..........................................193 Reeling up the hoist rope.............................................................194 6.2.13 Replacing the intermediate sections on the foot section............................195 Prerequisites.........................................................................195 When rigging..........................................................................196 When unrigging........................................................................197 6.2.14 Installing/removing sections of the luffing jib and rear pendant links.............198 Before the installation..............................................................198 Installing............................................................................198 Removing..............................................................................200 Rear pendant link transport protection...............................................202 6.2.15 Hinge lock in the foot section.....................................................203 Releasing the hinge lock..............................................................203 Locking the hinge.....................................................................205 6.2.16 Setting the angle of the luffing jib...............................................207 6.2.17 Placing and reeving the hoist rope.................................................209 Possible reeving methods..............................................................210 6.2.18 Opening the luffing jib submenu....................................................211 6.2.19 Telescoping with the luffing jib...................................................212 Prerequisites.........................................................................212 Telescoping with teleautomation.......................................................213 Telescoping with semi-automatic.......................................................215 6.2.20 Derricking luffing jib when rigging................................................217 Prerequisites.........................................................................217 6.2.21 Derricking main boom with installed luffing jib....................................219 Derricking between –1.5 to 82.......................................................219 Derricking between 80 and 60........................................................220 6.2.22 Putting the luffing jib into working position......................................221 Raising the luffing jib...............................................................221 Telescoping to fixed length...........................................................222 Lowering to working position.........................................................223 6.2.23 Preparing the luffing jib for unrigging............................................224 6.3 Operating with the luffing jib............................................................227 6.3.1 Operating the RCL...................................................................228 Entering the RCL code for the luffing jib.............................................228 Entering components for the luffing jib..............................................228 Accepting the rigging mode...........................................................230 Checks and displays in the Monitoring submenu.......................................231 6.3.2 RCL shutdown........................................................................233 6.3.3 Crane movements.....................................................................234 Controlling...........................................................................234 Derricking the main boom..............................................................234 Maximum power unit speeds.............................................................234 Shutdowns.............................................................................234 6.3.4 Working range and shutdowns.........................................................235 6.3.5 Checks when operating with the luffing jib..........................................237 Horizontal alignment.................................................................237 Checking the wind speed...............................................................237 7 Heavy load lattice extension....................................................................241 7.1 Rigging the heavy load lattice extension..................................................241 7.1.1 CHECKLIST: Rigging the heavy load lattice extension.................................241 7.1.2 CHECKLIST: Unrigging the heavy load lattice extension...............................245 7.2 Description of the rigging work...........................................................249 7.2.1 Truck crane rigging mode during installation of the heavy load lattice extension....249 7.2.2 Establishing/disconnecting the connections for the hydraulic lock...................250 Making the connections...............................................................250 Breaking the connections.............................................................251 7.2.3 Securing/releasing locks............................................................252 7.2.4 Handling the pins...................................................................253 7.2.5 Locking the adapter/releasing the pin...............................................254 Prerequisites.........................................................................254 Locking the adapter...................................................................254 Releasing the locking pin.............................................................255 7.2.6 Replacing deflection sheaves on the angle piece.....................................256 7.2.7 Installing/removing head section and angle piece....................................257 Installing............................................................................257 Removing..............................................................................257 7.2.8 Folding deflection sheaves up/down..................................................259 On the angle piece....................................................................259 On the adapter........................................................................260 7.2.9 Setting the angle position of the heavy load lattice extension......................261 7.2.10 Installing/removing the lifting limit switch.......................................263 Installing lifting limit switch.......................................................263 Removing the lifting limit switch....................................................264 7.2.11 Anemometer and air traffic control light...........................................265 Installing............................................................................265 Removing..............................................................................265 7.2.12 Establishing/disconnecting the electrical connection...............................266 Establishing aconnection.............................................................266 Disconnecting.........................................................................267 7.2.13 Placing and reeving hoist rope.....................................................268 Possible reeving methods..............................................................269 7.3 Operating the heavy load lattice extension................................................271 7.3.1 Operating the RCL...................................................................271 Entering the RCL code for the heavy load lattice extension...........................271 Entering components for the heavy load lattice extension..............................271 Accepting the rigging mode...........................................................273 Checks and displays in the Monitoring submenu.......................................274 7.3.2 RCL shutdown........................................................................275 7.3.3 Crane movements.....................................................................275 7.3.4 Telescoping with rigged heavy load lattice extension................................276 7.3.5 Checks when operating with the heavy load lattice extension.........................277 Horizontal alignment.................................................................277 Checking the wind speed...............................................................277 7.3.6 Notes on two-hook operation.........................................................278 8 Auxiliary single-sheave boom top................................................................281 8.1 Installing/removing.......................................................................281 8.1.1 Installing/removing the auxiliary single-sheave boom top............................281 Installing............................................................................281 Removing..............................................................................282 8.2 Rigging the auxiliary single-sheave boom top..............................................283 8.2.1 Rigging in working position/transport position......................................283 8.2.2 Attaching and removing the hoist rope...............................................284 Possible reeving methods..............................................................285 8.2.3 Lifting limit switch and anemometer.................................................286 Lifting limit switch..................................................................286 Installing and removing...............................................................287 8.3 Operation with the auxiliary single-sheave boom top.......................................288 8.3.1 Setting the RCL.....................................................................288 8.3.2 Derricking, telescoping the main boom...............................................288 8.3.3 Notes on RCL shutdown...............................................................289 8.3.4 Procedure if permissible wind speeds are exceeded...................................289 8.3.5 RCL display with the auxiliary single-sheave boom top folded up/rigged..............290 8.3.6 Notes on two-hook operation.........................................................290 9 Turning loads...................................................................................293 9.1 Requirements..............................................................................294 9.2 Setting the RCL to turn loads.............................................................295 Entering the reevings....................................................................295 Setting the RCL to the auxiliary hoist....................................................295 9.3 Turning a load............................................................................297 10 Rigging winch (additional equipment)...........................................................303 10.1 Overview.................................................................................303 Operating principle and accessories.......................................................303 10.2 Hand-held control........................................................................304 10.3 Pulling the hoist rope to the head.......................................................305 Requirements..............................................................................305 Remarks...................................................................................305 Rigging work on the sheaves for operating the rigging winch...............................306 Reeling off the rigging rope..............................................................307 Positioning the rigging rope..............................................................308 Connecting the rigging rope and the hoist rope............................................308 Unreeling the hoist rope..................................................................309 Separating the rigging rope and the hoist rope............................................310 Rolling the rigging rope onto the drum....................................................310 Rigging work on the sheaves for crane operation...........................................312 10.4 Pulling the hoist rope to the upper hook block...........................................313 Requirements..............................................................................313 Rigging work on the sheaves for operating the rigging winch...............................314 Reeling off the rigging rope..............................................................315 Positioning the rigging rope..............................................................316 Connecting the rigging rope and the main hoist rope.......................................317 Reeling off the main hoist rope...........................................................317 Separating the rigging rope and the main hoist rope.......................................317 Rolling the rigging rope onto the drum....................................................318 10.5 Rigging work.............................................................................319 10.5.1 For operation of the rigging winch.................................................319 Releasing the winch lock..............................................................319 Locking the winch.....................................................................319 Loosening the rigging rope at the rope attachment point...............................320 Fastening the rigging rope at the rope attachment point...............................321 Installing the rigging winch..........................................................321 Removing the rigging winch............................................................323 10.5.2 Connecting/disconnecting the electrical connection.................................324 Establishing..........................................................................324 Disconnecting.........................................................................324 10.5.3 Establishing/disconnecting the hydraulic connection................................325 Establishing..........................................................................325 Disconnecting.........................................................................325 10.5.4 Rigging on the foot section........................................................326 For operation of the rigging winch....................................................326 For crane operation...................................................................327 10.5.5 Guide sheaves......................................................................328 Inserting or removing the rigging rope................................................328 10.5.6 On the angle piece.................................................................329 For operation of the rigging winch....................................................329 For crane operation...................................................................329 10.5.7 On the head........................................................................330 For operation of the rigging winch....................................................330 For crane operation...................................................................330 10.5.8 Rope connector.....................................................................331 Establishing the connection...........................................................331 Undoing the connection................................................................333 11 Driving with rigged truck crane................................................................337 11.1 Driving distance.........................................................................338 11.2 Permissible rigging modes and axle loads.................................................338 11.2.1 Rigging modes with boom extension..................................................338 11.2.2 Rigging modes with luffing jib.....................................................339 11.2.3 Rigging modes with the heavy load lattice extension................................342 11.2.4 Rigging modes with the auxiliary single-sheave boom top............................342 11.3 Before driving the rigged truck crane....................................................343 11.4 Driving the rigged truck crane...........................................................343 Driving from the driver's cab.............................................................343 While driving.............................................................................343 11.5 Tables with boom positions and axle loads................................................345 Information about the tables..............................................................345 11.5.1 Boom extension with 3 angle.......................................................346 11.5.2 Boom extension with 25 angle......................................................346 11.5.3 Luffing jib........................................................................346 11.5.4 Heavy load lattice extension.......................................................346 11.5.5 Auxiliary single-sheave boom top...................................................346 12 Malfunctions...................................................................................349 12.1 Notes on troubleshooting.................................................................349 General information......................................................................349 What to do in theevent of malfunctions..................................................349 Fuses.....................................................................................349 ECOS malfunctions........................................................................349 RCL malfunctions..........................................................................349 12.2 Troubleshooting and remedies.............................................................351 12.2.1 Boom extension and heavy load lattice extension....................................351 12.2.2 Luffing jib........................................................................351 12.3 RCL malfunctions.........................................................................355 12.3.1 Table of lattice extension error codes.............................................356 12.3.2 Checking RCL supply lines and connections..........................................357 On the lattice extension..............................................................358 13 Maintenance....................................................................................361 13.1 Cleaning work............................................................................362 Overview of subassemblies easily damaged when cleaning....................................362 13.2 Maintenance plans........................................................................365 13.2.1 Maintenance plan M 1...............................................................365 13.2.2 Maintenance plan M 3...............................................................365 13.2.3 Maintenance plan Y 2...............................................................366 13.2.4 Maintenance plan Y 5...............................................................366 13.2.5 Maintenance plan Y 10..............................................................366 13.3 Boom extension and luffing jib...........................................................367 13.3.1 Lubricating the connecting and socket pins.........................................367 Grease, tools.........................................................................367 Prerequisites.........................................................................367 Checking..............................................................................367 Lubricating...........................................................................368 13.3.2 Lubricating the lower joint........................................................369 Grease, spare parts, tools............................................................369 Prerequisites.........................................................................369 Lubrication...........................................................................369 13.3.3 Checking the sheaves...............................................................370 13.3.4 Checking the nitrogen pressure and oil pressure in the fall-back guard strut.......371 Spare parts and tools.................................................................371 Prerequisites.........................................................................371 Test connections......................................................................372 Nitrogen pressure.....................................................................372 Oil pressure..........................................................................376 13.3.5 Required inspections for the fall-back guard strut.................................378 13.4 Rigging winch (additional equipment).....................................................379 13.4.1 Lubricating the bearings...........................................................379 Grease, spare parts, tools............................................................379 Prerequisites.........................................................................379 Lubricating...........................................................................379 13.4.2 Greasing the driving pinions.......................................................380 Grease, spare parts, tools............................................................380 Prerequisites.........................................................................380 Greasing..............................................................................380 13.4.3 Checking the condition of the rigging rope.........................................381 13.4.4 Changing the rigging rope..........................................................382 Spare parts and tools.................................................................382 Prerequisites.........................................................................382 Removing the old rope.................................................................382 Attaching a new rope..................................................................383 14 Index..........................................................................................387 A.............................................................................................389 B.............................................................................................389 C.............................................................................................389 F.............................................................................................389 H.............................................................................................389 I.............................................................................................390 L.............................................................................................390 M.............................................................................................391 O.............................................................................................391 P.............................................................................................392 R.............................................................................................392 S.............................................................................................393 T.............................................................................................393 W.............................................................................................393
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