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Grove GMK 6400 Lattice Extension Operating Instruction Manual 3112975 – PDF DOWNLOAD
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Description
Grove GMK 6400 Lattice Extension Operating Instruction Manual 3112975 – PDF DOWNLOAD
FILE DETAILS:
Grove GMK 6400 Lattice Extension Operating Instruction Manual 3112975 – PDF DOWNLOAD
Language : English
Pages : 400
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove 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
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 GMK 6400 Lattice Extension Operating Instruction Manual 3112975 – PDF DOWNLOAD
Operating Instructions Lattice extension.......................................................... 1 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 Additional page: Luffing jib – Reduction in transport height ..................................... 13 Luffing jib correction sheet ..................................................................... 17 1 Luffing jib – Fall-back guard strut maintenance work........................................ 17 Invalidation of the description........................................................... 17 1.1 Luffing control arm with fall-back guard strut........................................ 17 1.2 Maintenance interval for the fall-back guard strut.................................... 18 GROVE- Part numbers................................................................... 18 1.2.1 Visual inspection............................................................... 18 1.2.2 Pressure test................................................................... 18 1 Overview........................................................................................ 23 1.1 Accidents................................................................................. 23 1.2 Warranty.................................................................................. 23 1.3 Terms used................................................................................ 24 1.3.1 For the boom extension.............................................................. 24 1.3.2 For the luffing jib................................................................. 26 1.3.3 For the heavy load lattice extension................................................ 28 1.3.4 For the auxiliary single-sheave boom top............................................ 29 1.3.5 For operation of the rigging winch.................................................. 30 1.3.6 On the main boom.................................................................... 31 1.4 Notes about the lattice extension operating manual........................................ 33 1.4.1 What do the symbols used mean?...................................................... 33 1.4.2 Definitions of direction information................................................ 33 Basic rule............................................................................ 33 Switches and buttons................................................................. 34 General information on the operating elements......................................... 34 General rules for buttons and symbols................................................ 34 1.4.3 How are the operating instructions structured?...................................... 35 1.4.4 How do I find the information I need?............................................... 36 1.5 Conversion table for US measurements...................................................... 37 2 Basic safety instructions....................................................................... 41 2.1 Intended use.............................................................................. 41 2.2 Improper use.............................................................................. 42 2.3 Organisational measures................................................................... 42 2.4 Personnel qualifications.................................................................. 43 Requirements.............................................................................. 43 Training courses.......................................................................... 43 2.5 Safety instructions for working with the lattice extension............................... 44 2.6 Information on transporting persons....................................................... 45 3 For operations planning......................................................................... 49 3.1 Boom extension, luffing jib and heavy load lattice extension.............................. 49 3.1.1 Notes on assembly................................................................... 49 3.1.2 Assembly of the boom extension 3 inclined.......................................... 50 3.1.3 Assembly of the boom extension 25 inclined......................................... 56 3.1.4 Assembly of the luffing jib without inclination..................................... 60 3.1.5 Assembly of the luffing jib with inclination........................................ 64 3.1.6 Assembly of the heavy load lattice extension........................................ 66 3.1.7 Transport dimensions and weights.................................................... 67 Foot section in different combinations.............................................. 70 Intermediate sections pushed into each other......................................... 72 3.1.8 Identification...................................................................... 73 3.1.9 Slinging points..................................................................... 77 Slinging points on the foot section................................................... 79 3.1.10 Transport.......................................................................... 81 Applicable for all sections........................................................... 81 For the foot section/luffing control arm............................................. 81 For the head.......................................................................... 82 3.2 Auxiliary single-sheave boom top.......................................................... 83 3.2.1 Assembly............................................................................ 83 3.2.2 Identification and slinging point................................................... 83 3.2.3 Transport dimensions and weight..................................................... 84 4 Additional operating and display elements....................................................... 87 4.1 Overview of the operating elements........................................................ 87 4.1.1 On the crane control display........................................................ 87 Main menu............................................................................. 87 Luffing jib submenu.................................................................. 88 Power unit speeds submenu............................................................. 88 4.1.2 On the RCL display.................................................................. 89 Submenu for entering rigging mode..................................................... 89 Submenu for RCL monitoring............................................................ 89 4.1.3 On the hand-held control............................................................ 90 4.2 Brief description of the operating elements............................................... 91 4.2.1 On the crane control display........................................................ 91 In the power unit speed submenu....................................................... 91 In the Luffing jib submenu............................................................ 91 4.2.2 On the RCL display.................................................................. 99 Entering rigging mode in submenu...................................................... 99 In the RCL monitoring submenu.........................................................100 4.2.3 On the hand-held control............................................................101 Pre-selection.........................................................................101 Movements of the rigging winch........................................................102 5 Boom extension..................................................................................105 5.1 Checklists for rigging work...............................................................105 5.1.1 CHECKLIST: Rigging the boom extension...............................................105 5.1.2 CHECKLIST: Unrigging the boom extension.............................................111 5.2 Description of the rigging work...........................................................115 5.2.1 Pulling apart/pushing together intermediate sections................................115 Folding up/folding out holders........................................................115 Installing/removing the rear pendant links...........................................115 Pulling apart intermediate sections...................................................116 Pushing together intermediate sections...............................................117 5.2.2 Checking the bracing arms...........................................................118 5.2.3 Rigging mode of the truck crane at installation and removal.........................119 5.2.4 Establishing/disconnecting the connections for the hydraulic lock...................120 Making the connections...............................................................120 Breaking the connections.............................................................121 5.2.5 Securing/releasing locks............................................................122 5.2.6 Locking the foot section/releasing the lock.........................................123 Prerequisites.........................................................................123 Locking the foot section..............................................................123 Releasing the lock....................................................................124 5.2.7 Handling the pins...................................................................125 5.2.8 Installing/removing boom extension sections.........................................126 Before the installation...............................................................126 Installing............................................................................126 Removing..............................................................................127 5.2.9 Blocking the joint on the foot section..............................................128 5.2.10 Removing/installing the deflection sheave on the angle piece.......................129 5.2.11 Replacing deflection sheaves on the angle piece....................................130 5.2.12 Folding deflection sheaves up/down.................................................131 On the angle piece....................................................................131 On the foot section..................................................................132 5.2.13 Setting the angle position of the boom extension...................................133 5.2.14 Installing/removing the lifting limit switch.......................................135 Installing lifting limit switch.......................................................135 Removing the lifting limit switch....................................................136 5.2.15 Anemometer and air traffic control light...........................................137 Installing............................................................................137 Removing..............................................................................137 5.2.16 Electrical connection foot section/main boom.......................................138 Establishing..........................................................................138 Disconnecting.........................................................................138 5.2.17 Electric connection head/foot section..............................................139 Connecting cable......................................................................139 Establishing..........................................................................139 Disconnecting.........................................................................140 5.2.18 Placing and reeving the hoist rope.................................................142 Possible reeving methods..............................................................144 5.3 Operation with boom extension.............................................................147 5.3.1 Operating the RCL...................................................................148 Entering the RCL code.................................................................148 Enter components......................................................................148 Accepting the rigging mode...........................................................150 Checks and displays in the Monitoring submenu.........................................150 5.3.2 RCL shutdown........................................................................152 5.3.3 Crane movements.....................................................................152 5.3.4 Telescoping with rigged boom extension..............................................153 5.3.5 Checks when operating with the boom extension.......................................154 Horizontal alignment.................................................................154 Checking the wind speed...............................................................154 6 Luffing jib.....................................................................................159 6.1 Checklists for rigging work...............................................................159 6.1.1 CHECKLIST: Rigging the luffing jib..................................................159 6.1.2 CHECKLIST: Unrigging the luffing jib................................................167 6.2 Description of the rigging work...........................................................173 6.2.1 Ladder and railing..................................................................173 When rigging..........................................................................173 When unrigging........................................................................174 Railing on the luffing control arm....................................................176 6.2.2 Pulling apart/pushing together intermediate sections................................177 6.2.3 Checking the bracing arms...........................................................177 6.2.4 Rigging mode of the truck crane at installation and removal.........................177 6.2.5 Installing/removing the luffing control arm.........................................178 Installation..........................................................................178 Removal...............................................................................181 6.2.6 Raising/setting down the luffing control arm........................................184 Raising the luffing control arm.......................................................184 Setting down the luffing control arm..................................................184 6.2.7 Hand-held control...................................................................185 Moving the hoists.....................................................................185 Moving the rigging winch.............................................................185 6.2.8 Separating/connecting catcher 2 and raising cylinder................................186 Setting down/ raising catcher 2.......................................................186 Separating catcher 2 and the raising cylinder.........................................187 Connecting catcher 2 and raising cylinder............................................187 6.2.9 Reeving the auxiliary hoist rope to the upper hook block............................188 6.2.10 Preparing the upper hook block for rigging.........................................190 Before mounting the foot section......................................................190 After mounting the foot section.......................................................191 6.2.11 Fastening the upper hook block on the luffing control arm..........................191 Releasing the safety device on the upper hook block...................................191 Pulling the upper hook block towards the luffing control arm.........................192 Locking the upper hook block..........................................................193 6.2.12 Releasing the upper hook block from the luffing control arm........................195 Releasing the locking pin.............................................................195 Pulling the upper hook block towards the catcher......................................196 Securing the upper hook block in the catcher..........................................197 Reeling up the hoist rope.............................................................198 6.2.13 Replacing the intermediate sections on the foot section............................199 Prerequisites.........................................................................199 When rigging..........................................................................200 When unrigging........................................................................201 6.2.14 Installing/removing sections of the luffing jib and rear pendant links.............202 Before the installation..............................................................202 Installing............................................................................202 Removing..............................................................................204 Rear pendant link transport protection...............................................206 6.2.15 Hinge lock in the foot section.....................................................207 Releasing the hinge lock..............................................................207 Locking the hinge.....................................................................209 6.2.16 Setting the angle of the luffing jib...............................................211 6.2.17 Placing and reeving the hoist rope.................................................213 Possible reeving methods..............................................................214 6.2.18 Opening the luffing jib submenu....................................................215 6.2.19 Telescoping with the luffing jib...................................................216 Prerequisites.........................................................................216 Telescoping with teleautomation.......................................................217 Telescoping with semi-automatic.......................................................219 6.2.20 Derricking luffing jib when rigging................................................221 Prerequisites.........................................................................221 6.2.21 Derricking main boom with installed luffing jib....................................223 Derricking between –1.5 to 82 .......................................................223 Derricking between 80 and 60 ........................................................224 6.2.22 Putting the luffing jib into working position......................................225 Raising the luffing jib...............................................................225 Telescoping to fixed length...........................................................226 Lowering to working position.........................................................227 6.2.23 Preparing the luffing jib for unrigging............................................228 6.3 Operating with the luffing jib............................................................231 6.3.1 Operating the RCL...................................................................232 Entering the RCL code for the luffing jib.............................................232 Entering components for the luffing jib..............................................232 Accepting the rigging mode...........................................................234 Checks and displays in the Monitoring submenu.......................................235 6.3.2 RCL shutdown........................................................................237 6.3.3 Crane movements.....................................................................238 Controlling...........................................................................238 Derricking the main boom..............................................................238 Maximum power unit speeds.............................................................238 Shutdowns.............................................................................238 6.3.4 Working range and shutdowns.........................................................239 6.3.5 Checks when operating with the luffing jib..........................................241 Horizontal alignment.................................................................241 Checking the wind speed...............................................................241 7 Heavy load lattice extension....................................................................245 7.1 Rigging the heavy load lattice extension..................................................245 7.1.1 CHECKLIST: Rigging the heavy load lattice extension.................................245 7.1.2 CHECKLIST: Unrigging the heavy load lattice extension...............................249 7.2 Description of the rigging work...........................................................253 7.2.1 Truck crane rigging mode during installation of the heavy load lattice extension....253 7.2.2 Establishing/disconnecting the connections for the hydraulic lock...................254 Making the connections...............................................................254 Breaking the connections.............................................................255 7.2.3 Securing/releasing locks............................................................256 7.2.4 Handling the pins...................................................................257 7.2.5 Locking the adapter/releasing the pin...............................................258 Prerequisites.........................................................................258 Locking the adapter...................................................................258 Releasing the locking pin.............................................................259 7.2.6 Replacing deflection sheaves on the angle piece.....................................260 7.2.7 Installing/removing head section and angle piece....................................261 Installing............................................................................261 Removing..............................................................................261 7.2.8 Folding deflection sheaves up/down..................................................263 On the angle piece....................................................................263 On the adapter........................................................................264 7.2.9 Setting the angle position of the heavy load lattice extension......................265 7.2.10 Installing/removing the lifting limit switch.......................................267 Installing lifting limit switch.......................................................267 Removing the lifting limit switch....................................................268 7.2.11 Anemometer and air traffic control light...........................................269 Installing............................................................................269 Removing..............................................................................269 7.2.12 Establishing/disconnecting the electrical connection...............................270 Establishing aconnection.............................................................270 Disconnecting.........................................................................271 7.2.13 Placing and reeving hoist rope.....................................................272 Possible reeving methods..............................................................273 7.3 Operating the heavy load lattice extension................................................275 7.3.1 Operating the RCL...................................................................275 Entering the RCL code for the heavy load lattice extension...........................275 Entering components for the heavy load lattice extension..............................275 Accepting the rigging mode...........................................................277 Checks and displays in the Monitoring submenu.......................................278 7.3.2 RCL shutdown........................................................................279 7.3.3 Crane movements.....................................................................279 7.3.4 Telescoping with rigged heavy load lattice extension................................280 7.3.5 Checks when operating with the heavy load lattice extension.........................281 Horizontal alignment.................................................................281 Checking the wind speed...............................................................281 7.3.6 Notes on two-hook operation.........................................................282 8 Auxiliary single-sheave boom top................................................................285 8.1 Installing/removing.......................................................................285 8.1.1 Installing/removing the auxiliary single-sheave boom top............................285 Installing............................................................................285 Removing..............................................................................286 8.2 Rigging the auxiliary single-sheave boom top..............................................287 8.2.1 Rigging in working position/transport position......................................287 8.2.2 Attaching and removing the hoist rope...............................................288 Possible reeving methods..............................................................289 8.2.3 Lifting limit switch and anemometer.................................................290 Lifting limit switch..................................................................290 Installing and removing...............................................................291 8.3 Operation with the auxiliary single-sheave boom top.......................................292 8.3.1 Setting the RCL.....................................................................292 8.3.2 Derricking, telescoping the main boom...............................................292 8.3.3 Notes on RCL shutdown...............................................................293 8.3.4 Procedure if permissible wind speeds are exceeded...................................293 8.3.5 RCL display with the auxiliary single-sheave boom top folded up/rigged..............294 8.3.6 Notes on two-hook operation.........................................................294 9 Turning loads...................................................................................297 9.1 Requirements..............................................................................298 9.2 Setting the RCL to turn loads.............................................................299 Entering the reevings....................................................................299 Setting the RCL to the auxiliary hoist....................................................299 9.3 Turning a load............................................................................301 10 Rigging winch (additional equipment)...........................................................307 10.1 Overview.................................................................................307 Operating principle and accessories.......................................................307 10.2 Hand-held control........................................................................308 10.3 Pulling the hoist rope to the head.......................................................309 Requirements..............................................................................309 Remarks...................................................................................309 Rigging work on the sheaves for operating the rigging winch...............................310 Reeling off the rigging rope..............................................................311 Positioning the rigging rope..............................................................312 Connecting the rigging rope and the hoist rope............................................312 Unreeling the hoist rope..................................................................313 Separating the rigging rope and the hoist rope............................................314 Rolling the rigging rope onto the drum....................................................314 Rigging work on the sheaves for crane operation...........................................316 10.4 Pulling the hoist rope to the upper hook block...........................................317 Requirements..............................................................................317 Rigging work on the sheaves for operating the rigging winch...............................318 Reeling off the rigging rope..............................................................319 Positioning the rigging rope..............................................................320 Connecting the rigging rope and the main hoist rope.......................................321 Reeling off the main hoist rope...........................................................321 Separating the rigging rope and the main hoist rope.......................................321 Rolling the rigging rope onto the drum....................................................322 10.5 Rigging work.............................................................................323 10.5.1 For operation of the rigging winch.................................................323 Releasing the winch lock..............................................................323 Locking the winch.....................................................................323 Loosening the rigging rope at the rope attachment point...............................324 Fastening the rigging rope at the rope attachment point...............................325 Installing the rigging winch..........................................................325 Removing the rigging winch............................................................327 10.5.2 Connecting/disconnecting the electrical connection.................................328 Establishing..........................................................................328 Disconnecting.........................................................................328 10.5.3 Establishing/disconnecting the hydraulic connection................................329 Establishing..........................................................................329 Disconnecting.........................................................................329 10.5.4 Rigging on the foot section........................................................330 For operation of the rigging winch....................................................330 For crane operation...................................................................331 10.5.5 Guide sheaves......................................................................332 Inserting or removing the rigging rope................................................332 10.5.6 On the angle piece.................................................................333 For operation of the rigging winch....................................................333 For crane operation...................................................................333 10.5.7 On the head........................................................................334 For operation of the rigging winch....................................................334 For crane operation...................................................................334 10.5.8 Rope connector.....................................................................335 Establishing the connection...........................................................335 Undoing the connection................................................................337 11 Driving with rigged truck crane................................................................341 11.1 Driving distance.........................................................................342 11.2 Permissible rigging modes and axle loads.................................................342 11.2.1 Rigging modes with boom extension..................................................342 11.2.2 Rigging modes with luffing jib.....................................................343 11.2.3 Rigging modes with the heavy load lattice extension................................346 11.2.4 Rigging modes with the auxiliary single-sheave boom top............................346 11.3 Before driving the rigged truck crane....................................................347 11.4 Driving the rigged truck crane...........................................................347 Driving from the driver's cab.............................................................347 While driving.............................................................................347 11.5 Tables with boom positions and axle loads................................................349 Information about the tables..............................................................349 11.5.1 Boom extension with 3 angle.......................................................350 11.5.2 Boom extension with 25 angle......................................................350 11.5.3 Luffing jib........................................................................350 11.5.4 Heavy load lattice extension.......................................................350 11.5.5 Auxiliary single-sheave boom top...................................................350 12 Malfunctions...................................................................................353 12.1 Notes on troubleshooting.................................................................353 General information......................................................................353 What to do in theevent of malfunctions..................................................353 Fuses.....................................................................................353 ECOS malfunctions........................................................................353 RCL malfunctions..........................................................................353 12.2 Troubleshooting and remedies.............................................................355 12.2.1 Boom extension and heavy load lattice extension....................................355 12.2.2 Luffing jib........................................................................355 12.3 RCL malfunctions.........................................................................359 12.3.1 Table of lattice extension error codes.............................................360 12.3.2 Checking RCL supply lines and connections..........................................361 On the lattice extension..............................................................362 13 Maintenance....................................................................................365 13.1 Cleaning work............................................................................366 Overview of subassemblies easily damaged when cleaning....................................366 13.2 Maintenance plans........................................................................369 13.2.1 Maintenance plan M 1...............................................................369 13.2.2 Maintenance plan M 3...............................................................369 13.2.3 Maintenance plan Y 2...............................................................370 13.2.4 Maintenance plan Y 5...............................................................370 13.2.5 Maintenance plan Y 10..............................................................370 13.3 Boom extension and luffing jib...........................................................371 13.3.1 Lubricating the connecting and socket pins.........................................371 Grease, tools.........................................................................371 Prerequisites.........................................................................371 Checking..............................................................................371 Lubricating...........................................................................372 13.3.2 Lubricating the lower joint........................................................373 Grease, spare parts, tools............................................................373 Prerequisites.........................................................................373 Lubrication...........................................................................373 13.3.3 Checking the sheaves...............................................................374 13.3.4 Checking the nitrogen pressure and oil pressure in the fall-back guard strut.......375 Spare parts and tools.................................................................375 Prerequisites.........................................................................375 Test connections......................................................................376 Nitrogen pressure.....................................................................376 Oil pressure..........................................................................380 13.3.5 Required inspections for the fall-back guard strut.................................382 13.4 Rigging winch (additional equipment).....................................................383 13.4.1 Lubricating the bearings...........................................................383 Grease, spare parts, tools............................................................383 Prerequisites.........................................................................383 Lubricating...........................................................................383 13.4.2 Greasing the driving pinions.......................................................384 Grease, spare parts, tools............................................................384 Prerequisites.........................................................................384 Greasing..............................................................................384 13.4.3 Checking the condition of the rigging rope.........................................385 13.4.4 Changing the rigging rope..........................................................386 Spare parts and tools.................................................................386 Prerequisites.........................................................................386 Removing the old rope.................................................................386 Attaching a new rope..................................................................387 14 Index..........................................................................................391 A.............................................................................................393 B.............................................................................................393 C.............................................................................................393 F.............................................................................................393 H.............................................................................................393 I.............................................................................................394 L.............................................................................................394 M.............................................................................................395 O.............................................................................................395 P.............................................................................................396 R.............................................................................................396 S.............................................................................................397 T.............................................................................................397 W.............................................................................................397
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