Grove Crane GMK 6400 Mega Wing Lift Operating Instruction Manual 3112978 – PDF DOWNLOAD

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Grove Crane GMK 6400 Mega Wing Lift Operating Instruction Manual 3112978 – PDF DOWNLOAD

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Grove Crane GMK 6400 Mega Wing Lift Operating Instruction Manual 3112978 – PDF DOWNLOAD

Language : English
Pages : 350
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Grove Crane GMK 6400 Mega Wing Lift Operating Instruction Manual 3112978 – PDF DOWNLOAD

Basic safety instructions:

• In principle, the basic safety instructions apply from the Operating Instruc- tions. The basic
  safety instructions as regards the MWL supplied for the truck crane have been given below.
  Information regarding the used warnings and symbols; à Operating Instructions.

 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.
• 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 MWL accord- the Maintenance chapter.

Improper use:

• Manitowoc Crane Group Germany GmbH is not liable for damage resulting from the improper or
  unauthorised use of the GMK 6400 truck crane. The user alone assumes full responsibility for any
  risk.
• In addition to the following specifications, also observe the information regarding improper use in
  the Operating Instructions.

Organisational measures:
In addition to the following specifications, also observe the organisational measures in the
Operating Instructionsand 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.
• Responsibilities related to crane operation, rigging, maintenance 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.
• Welding work on load-bearing parts may only be carried out by qualified personnel with the
  manufacturer’s prior permission. To avoid any damage, especially to electronic components, you must
  take certain precautions before performing any welding work. You should therefore always consult
  Manitowoc Crane Care before carrying out any welding work.
• Spare parts must fulfil the technical requirements defined by the manufac- turer. Genuine spare
  parts always meet these requirements.
• Only trained staff must be used when rigging the MWL.
• The crane cab must not be tilted once the rear pendant links of the MWL
  have been fitted.

TABLE OF CONTENTS:

Grove Crane GMK 6400 Mega Wing Lift Operating Instruction Manual 3112978 – PDF DOWNLOAD

Additional page: Rest for rear pendant link......................................................  3
Additional page: Transport position of rests A and B.............................................  5
	Rest A.......................................................................................  5
	Rest B.......................................................................................  6
Additional page: Assembly aid....................................................................  9
	Installation and removal.....................................................................  9
	Transportation and storage................................................................... 10
Additional page: Driving mode supplement......................................................... 13
1 Overview....................................................................................... 19
	1.1 Accidents................................................................................ 19
	1.2 Warranty................................................................................. 19
	1.3 Terms used............................................................................... 20
	1.4 Function of the MWL...................................................................... 24
	1.5 Notes about the MWL operating manual..................................................... 26
		1.5.1 Abbreviation used.................................................................. 26
		1.5.2 What do the symbols used mean?..................................................... 26
		1.5.3 Definition of positional references................................................ 26
			Basic rule........................................................................... 26
			Switches and buttons................................................................ 27
			General information on theoperating elements...................................... 27
			General rules for buttons and symbols............................................... 27
		1.5.4 How is the operating manual structured?............................................ 28
		1.5.5 How do I find the information I need?.............................................. 29
	1.6 Supplementary instructions to the operating manual....................................... 30
		1.6.1 Addition to the driving mode table................................................. 30
		1.6.2 Addition to the Telescoping emergency programme submenu............................ 30
		1.6.3 Addition to operations planning.................................................... 31
			Thresholds for the use of the main hoist............................................. 31
		1.6.4 Rigging modes for rigging at 0 to the rear........................................ 33
	1.7 Conversion table for US measurements..................................................... 34
2 Basic safety instructions...................................................................... 37
	2.1 Intended use............................................................................. 37
	2.2 Improper use............................................................................. 38
	2.3 Organisational measures.................................................................. 38
	2.4 Qualifications of the personnel.......................................................... 39
		Requirements............................................................................. 39
		Training courses......................................................................... 39
	2.5 Safety instructions for working with the MWL............................................. 40
	2.6 Information on transporting persons...................................................... 41
3 For operations planning........................................................................ 45
	3.1 Dimensions and weights................................................................... 45
		3.1.1 Parts on the truck crane........................................................... 45
		3.1.2 Additional parts................................................................... 46
		3.1.3 Mega Wing Lift (MWL)............................................................... 46
	3.2 Identification........................................................................... 47
	3.3 Slinging points.......................................................................... 48
	3.4 Transportation........................................................................... 49
		Transport condition of the MWL........................................................... 50
		For parts on the truck crane............................................................. 50
4 Additional operating and display elements...................................................... 53
	4.1 Location of the additional operating and display elements............................... 53
		4.1.1 On the crane control display....................................................... 53
			In the main menu..................................................................... 53
			Submenu Operation-MWL............................................................... 54
			Submenu RiggingMWL................................................................. 56
			In the luffing jib submenu........................................................... 58
		4.1.2 On the RCL display................................................................. 59
		4.1.3 On the hand-held control........................................................... 60
	4.2 Function of the additional operating and display elements............................... 61
		4.2.1 In the main menu and in the luffing jib submenu.................................... 61
		4.2.2 In the Operation-MWL submenu....................................................... 61
		4.2.3 In the submenu Rigging-MWL......................................................... 71
		4.2.4 On the SLI display – "Enter rigging mode" submenu.................................. 77
		4.2.5 On the hand-held control........................................................... 78
			Connections for hand-held control.................................................... 78
			Selector switch for rigging.......................................................... 79
			Two-hand control panel............................................................... 82
5 Rigging and unrigging the MWL.................................................................. 87
	5.1 Checklists for rigging work.............................................................. 87
		5.1.1 CHECKLIST: Rigging the MWL......................................................... 87
		5.1.2 CHECKLIST: Unrigging the MWL....................................................... 93
	5.2 Rigging work............................................................................. 97
		5.2.1 Installing/removing the rests for the rear pendant links........................... 97
			Installing the rests................................................................. 97
			Folding out the rests................................................................ 99
			Folding in rests.....................................................................101
			Removing the rests...................................................................102
		5.2.2 Installing/removing the extension for the lower head sheave axle...................105
			Installing an extension..............................................................105
			Removing the extension...............................................................107
		5.2.3 Installing/removing the extension for the main boom pivot pin......................109
			Installing an extension..............................................................109
			Removing the extension...............................................................111
		5.2.4 Installing/removing the rear pendant links A.......................................113
			Installing and securing the rear pendant links A.....................................113
			Removing rear pendant link A.........................................................115
		5.2.5 Setting the MWL down on the carrier/raising the MWL................................116
			Setting down.........................................................................116
			Lifting..............................................................................117
		5.2.6 Installing/removing the spreader...................................................118
		5.2.7 Folding in/folding out the folding frame...........................................119
			Folding out the folding frame........................................................119
			Folding in the folding frame........................................................120
		5.2.8 Pushing in/pulling out the supports................................................121
		5.2.9 Connecting/disconnecting the rear pendant links....................................122
			Connecting the rear pendant links....................................................122
			Disconnecting the rear pendant links.................................................123
		5.2.10 Moving the turnbuckle into the transportation/operation position..................125
			Transportation position..............................................................125
			Operation position...................................................................126
		5.2.11 Greasing the peg on the holding frame.............................................126
		5.2.12 Establishing/disconnecting the hydraulic connections..............................127
			Establishing.........................................................................127
			Disconnecting........................................................................127
		5.2.13 Establishing/disconnecting electrical connections.................................128
			Establishing.........................................................................128
			Disconnecting........................................................................128
		5.2.14 Checking the raising cylinder stop................................................129
			Inspection...........................................................................129
		5.2.15 Setting the main boom down in the holding frame...................................131
		5.2.16 Locking/unlocking the MWL to/from the main boom...................................132
			Locking..............................................................................132
			Unlocking............................................................................133
		5.2.17 Connecting/detaching the deflection sheaves to/from the lower head sheave axle....135
			Connecting...........................................................................135
			Disconnecting........................................................................136
		5.2.18 Raising/setting down the MWL......................................................137
			Prerequisites........................................................................137
			Raising..............................................................................137
			Setting down.........................................................................138
		5.2.19 Locking/unlocking the winch.......................................................140
			Prerequisites........................................................................140
			Locking/unlocking the winch..........................................................140
		5.2.20 Winding/unwinding the winches.....................................................141
			Prerequisites........................................................................141
			Winding/unwinding the winches........................................................141
	5.3 Operation from the crane cab during rigging..............................................143
		Prerequisites............................................................................143
		Menus....................................................................................143
		5.3.1 Raising/setting down the MWL.......................................................144
			Raise MWL............................................................................144
			Setting down the MWL.................................................................145
		5.3.2 Locking/unlocking the winch........................................................147
			Locking/unlocking the winches........................................................147
			Unlocking winches....................................................................148
		5.3.3 Winding/unwinding the winches......................................................149
		5.3.4 Folding in the gantry masts........................................................150
6 Operation with the main boom and the MWL.......................................................153
	6.1 Operation with braced boom system........................................................154
		6.1.1 CHECKLIST: Putting the boom system into the operating condition...................154
		6.1.2 CHECKLIST: Putting the boom system into rigging mode...............................155
		6.1.3 Setting the RCL....................................................................156
		6.1.4 Opening the submenu Operation – MWL................................................158
		6.1.5 Telescoping with rigged MWL........................................................159
			Prerequisites........................................................................159
			Telescoping..........................................................................159
		6.1.6 Folding the gantry masts out/in....................................................161
			Prerequisites........................................................................161
			Folding in/folding out...............................................................161
		6.1.7 Bracing the boom system............................................................163
			Prerequisites........................................................................163
			Derricking to the bracing angle......................................................163
			Bracing..............................................................................164
		6.1.8 Locking/unlocking the winches......................................................166
			Locking winches......................................................................166
			Unlocking winches....................................................................167
	6.2 Operation with the MWL set down..........................................................169
		6.2.1 Putting the boom system into the operating condition...............................169
			Setting the RCL......................................................................170
			Telescoping..........................................................................171
			Derricking...........................................................................171
			Main boom operation.................................................................171
		6.2.2 Putting the boom system into rigging mode..........................................171
	6.3 Operation with unbraced boom system and raised MWL.......................................173
		6.3.1 Putting the boom system into the operating condition...............................173
			Setting the RCL......................................................................173
			Telescoping..........................................................................174
			Derricking...........................................................................174
			Main boom operation.................................................................174
		6.3.2 Putting the boom system into rigging mode..........................................175
	6.4 Driving with a rigged truck crane and rigged MWL.........................................177
		6.4.1 Driving distance...................................................................178
		6.4.2 Permissible rigging modes and axle loads...........................................178
		6.4.3 Permissible rigging modes and axle loads with main boom............................179
			Axle load tables.....................................................................180
	6.5 Driving..................................................................................181
		Before driving...........................................................................181
		Driving from the driver's cab............................................................181
		While driving............................................................................181
		After driving............................................................................182
		If necessary, rig the counterweight sections.............................................182
7 Operation with boom extension and MWL..........................................................185
	7.1 Further rigging work.....................................................................187
		7.1.1 CHECKLIST: Rigging for operation with boom extension...............................187
		7.1.2 CHECKLIST: Unrigging after operation with the boom extension......................188
		7.1.3 Extra information on positioning the hoist rope with the MWL rigged................189
	7.2 Operation with braced boom system........................................................191
		7.2.1 CHECKLIST: Putting the boom system into the operating condition...................191
		7.2.2 CHECKLIST: Putting the boom system into rigging mode...............................192
		7.2.3 Setting the RCL....................................................................193
	7.3 Rigging work.............................................................................195
		7.3.1 Installing/removing the bracing arms...............................................195
			Installing...........................................................................195
			Removing.............................................................................196
		7.3.2 Folding out/folding in the bracing arms............................................198
			Folding out..........................................................................198
			Folding in...........................................................................199
		7.3.3 Shifting the deflection sheaves....................................................200
			From the main boom to the bracing arm...............................................200
			From the bracing arm onto the main boom..............................................201
	7.4 Operation with MWL set down..............................................................203
		7.4.1 Putting the boom system into the operating condition...............................203
			Setting the RCL......................................................................204
			Telescoping..........................................................................205
			Operation with boom extension........................................................205
		7.4.2 Putting the boom system into rigging mode..........................................205
	7.5 Rigging mode with unbraced boom system and raised MWL....................................207
	7.6 Driving with rigged crane and rigged boom extension with rigged MWL......................209
		7.6.1 Driving distance...................................................................209
		7.6.2 Rigging modes for moving and axle loads............................................210
			Putting the truck crane into the rigging mode.......................................210
			12 m (39 ft)-boom extension..........................................................212
			18 m (59ft)-boom extension..........................................................213
			24 m (79 ft)-boom extension..........................................................214
		7.6.3 Driving............................................................................215
			Before driving.......................................................................215
			Driving from the driver's cab........................................................215
			While driving........................................................................215
			After driving........................................................................216
			If necessary, rig the counterweight sections.........................................216
8 Operation with luffing jib and MWL.............................................................219
	8.1 Further rigging work.....................................................................221
		8.1.1 CHECKLIST: Rigging for operation with luffing jib..................................221
		8.1.2 CHECKLIST: Unrigging after operation with the luffing jib..........................222
	8.2 Operation with braced boom system........................................................223
		8.2.1 CHECKLIST: Putting the boom system into the operating condition...................223
		8.2.2 CHECKLIST: Putting the boom system into rigging mode...............................227
		8.2.3 Setting the RCL....................................................................231
		8.2.4 Derricking main boom with rigged luffing jib and rigged MWL........................233
		8.2.5 Telescoping the main boom with rigged luffing jib and rigged MWL...................234
		8.2.6 Bracing the boom system with rigged luffing jib....................................236
	8.3 Operation with MWL set down..............................................................237
		8.3.1 Putting the boom system into the operating condition...............................237
			Setting the RCL......................................................................238
			Telescoping..........................................................................239
			Operating with the luffing jib.......................................................239
		8.3.2 Putting the boom system into rigging mode..........................................239
	8.4 Rigging mode with unbraced boom system and raised MWL....................................241
	8.5 Driving with rigged crane and rigged luffing jib with rigged MWL.........................243
		8.5.1 Driving distance...................................................................243
		8.5.2 Rigging modes for moving and axle loads............................................244
			Information about the tables.........................................................248
			25m (82ft) luffing jib.............................................................248
			31 m (102 ft) luffing jib...........................................................249
			37 m (121 ft) luffing jib...........................................................249
			43 m (141 ft) luffing jib...........................................................250
			49 m (161 ft) luffing jib...........................................................250
			55 m (180 ft) luffing jib...........................................................251
			61 m (200 ft) luffing jib...........................................................251
			67 m (220 ft) luffing jib...........................................................252
			73 m (240 ft) luffing jib...........................................................252
		8.5.3 Driving............................................................................253
			Before driving.......................................................................253
			Driving from the driver's cab........................................................253
			While driving........................................................................253
			After driving........................................................................254
			If necessary, rig the counterweight sections.........................................254
9 Operation with heavy load lattice extension and MWL............................................257
	9.1 Further rigging work.....................................................................259
		9.1.1 Rigging for operation with heavy load lattice extension............................259
		9.1.2 Unrigging after operation with the heavy load lattice extension....................260
	9.2 Operation with braced boom system........................................................261
		9.2.1 CHECKLIST: Putting the boom system into the operating condition...................261
		9.2.2 CHECKLIST: Putting the boom system into rigging mode...............................262
		9.2.3 Setting the RCL....................................................................263
	9.3 Operation with MWL set down..............................................................265
		9.3.1 Putting the boom system into the operating condition...............................265
			Setting the RCL......................................................................265
			Telescoping..........................................................................266
			Operation with the heavy load lattice extension.....................................266
		9.3.2 Putting the boom system into rigging mode..........................................267
	9.4 Rigging mode with unbraced boom system and raised MWL....................................269
	9.5 Turning loads with the heavy load lattice extension......................................271
		9.5.1 Prerequisites......................................................................272
		9.5.2 Setting the RCL for turning the load...............................................273
		9.5.3 Turning a load.....................................................................274
	9.6 Driving with rigged crane and rigged heavy load lattice extension with rigged MWL........277
		9.6.1 Driving distance...................................................................277
		9.6.2 Rigging modes for moving and axle loads............................................278
			Putting the truck crane into the rigging mode.......................................278
			4 m (13 ft)-heavy load lattice extension.............................................280
			7.5 m (25 ft)-heavy load lattice extension...........................................281
		9.6.3 Driving............................................................................282
			Before driving.......................................................................282
			Driving from the driver's cab........................................................282
			While driving........................................................................282
			After driving........................................................................283
			If necessary, rig the counterweight sections.........................................283
10 Errors during operation with the MWL..........................................................287
	10.1 Electrical system.......................................................................288
		10.1.1 Fuses.............................................................................288
	10.2 Troubleshooting.........................................................................289
		10.2.1 Errors during operation with the MWL..............................................289
		10.2.2 Errors when operating with the hand-held control..................................292
		10.2.3 Error messages on the RCL.........................................................293
			Check the supply line................................................................295
			Place the luffing jib on the floor during rigging....................................295
		10.2.4 Error messages on the crane control display.......................................296
	10.3 Operation with emergency programme switched on..........................................297
		10.3.1 Operating the MWL in the emergency programme......................................297
			Switching on the emergency programme................................................297
			Operating the MWL....................................................................299
		10.3.2 Telescoping in the emergency programme with a rigged MWL..........................301
			When retracting......................................................................301
			When extending.......................................................................302
11 Maintenance...................................................................................305
	11.1 Cleaning................................................................................306
		Overview of subassemblies easily damaged when cleaning...................................306
	11.2 Maintenance plans.......................................................................308
		11.2.1 Maintenance plan D................................................................308
		11.2.2 Maintenance plan W................................................................308
		11.2.3 Maintenance plan M 3..............................................................309
		11.2.4 Maintenance plan M 6..............................................................309
		11.2.5 Maintenance plan M 12.............................................................309
	11.3 Lubricants..............................................................................311
		11.3.1 Use of lubricant..................................................................311
	11.4 Maintenance work........................................................................313
		11.4.1 Check the lubrication on the gear rims............................................313
			Prerequisites........................................................................313
			Checking.............................................................................313
		11.4.2 Checking the guy ropes on the winch drum..........................................314
			Prerequisites........................................................................314
			Checking.............................................................................314
		11.4.3 Checking the deflection sheaves...................................................315
			Spare parts and tools................................................................315
			Prerequisites........................................................................315
			Checking.............................................................................315
		11.4.4 General control of the winch gears................................................317
			Prerequisites........................................................................317
			Checking.............................................................................317
		11.4.5 Checking the oil level in the winch gears.........................................317
			Prerequisites........................................................................317
			Checking.............................................................................317
		11.4.6 Checking the end fastenings of the guy ropes......................................318
			Spare parts and tools................................................................318
			Prerequisites........................................................................318
			Check at the gantry masts...........................................................318
			Check at the winch drums.............................................................319
		11.4.7 Lubricating the guy ropes.........................................................320
			Grease, spare parts and tools........................................................320
			Lubricating the rope.................................................................320
		11.4.8 Lubricating other lubricating points..............................................320
			Prerequisites........................................................................320
			Lubricating..........................................................................320
		11.4.9 Lubricating the winch gears.......................................................322
			Prerequisites........................................................................322
			Lubricating..........................................................................322
		11.4.10 Lubricate gear rims..............................................................323
			Spare parts and tools................................................................323
			Prerequisites........................................................................323
			Lubricating..........................................................................323
		11.4.11 Checking the condition of the guy ropes..........................................324
			Spare parts and tools................................................................324
			Prerequisites........................................................................324
			Checking.............................................................................324
		11.4.12 Lubricating the locking units....................................................326
			Prerequisites........................................................................326
			Lubricating..........................................................................326
		11.4.13 Changing the oil at the winch gears..............................................327
			Prerequisites........................................................................327
			Changing the oil.....................................................................327
			Checking the oil.....................................................................328
		11.4.14 Changing the guy ropes...........................................................329
			Information on changing ropes........................................................329
			Spare parts and tools................................................................329
			Prerequisites........................................................................329
			Removing the guy rope................................................................330
			Attaching a new guy rope.............................................................331
	11.5 Spare parts required for maintenance....................................................335
12 Index.........................................................................................339
	A............................................................................................341
	B............................................................................................341
	C............................................................................................341
	D............................................................................................341
	E............................................................................................342
	F............................................................................................342
	H............................................................................................342
	I............................................................................................342
	L............................................................................................343
	M............................................................................................343
	O............................................................................................344
	P............................................................................................346
	R............................................................................................346
	S............................................................................................347
	T............................................................................................347
	U............................................................................................347
	W............................................................................................347

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