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GROVE GMK 6400
Manitowoc GROVE GMK 6400
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3 112 993 en
12.07.2013
Operating manual
Part 1 – Driving
2
Table of Contents
Main Page
1 1 Overview
27
Default Chapter
27
Table of Contents
27
Overview
29
Accidents
29
Branch Offices
30
Manitowoc Crane Care
30
Dealer List
30
Warranty Specifications
30
Terms Used
32
Technical Data
35
Maximum Lifting Capacity
35
Dimensions and Weights of the Truck Crane, Axle Loads
36
Dimensions and Weights of Removable Parts
38
Carrier
41
Superstructure
45
Documentation Supplied
47
Questions on Documentation
48
Notes on the Operating Instructions
49
What Do the Symbols Used Mean
49
How Are the Operating Instructions Structured
51
How Do I Find the Information I Need
53
What Information Is Available for Operations Planning
56
Conversion Table for US Measuring Units
57
Training - Information
59
Identification
60
EC Declaration of Conformity
62
2 2 Basic Safety Instructions
63
Basic Safety Instructions
65
Intended Use
65
Improper Use
66
Organisational Measures
67
Qualifications of the Staff
69
Safety Instructions for Crane Operation
70
Safety Instructions for Driving the Truck Crane
70
Notes on Transporting Persons
72
3 3 Operating Elements for Driving
75
Operating Elements for Driving
77
Overview of the Operating Elements
77
On the Outside of the Truck Crane
78
Driver's Cab
80
Instrument Panel
81
27 Display, Driving Mode
87
Steering Column/Steering Wheel
89
Transmission Operating Elements
90
Tachograph
91
ECOS Control Unit
92
ECOS Display - Main Menu
94
ECOS Display - Submenus
96
Heating/Air-Conditioning System
102
Sockets for Hand-Held Control
104
Outrigger Control Units
105
Control Unit of the Rear Outrigger Box
106
Short Description of the Operating Elements
107
Definition of Direction Information
107
General Notes on the Operating Elements
108
General Rules for Buttons and Symbols on the Display
109
Engine
110
DEF System
113
Electrical System
115
Transmission
118
Reverse Camera
122
Final Drive
123
Brakes
124
Steering/Separate Steering
126
Suspension
129
Control Unit of the Rear Outrigger Box
130
Lighting/Windscreen Wipers/Horn
131
Level Adjustment System
134
Tachograph/Speedometer
136
Diagnostics
137
Windows, Doors, Keys
138
Front Flap
140
4 4 Starting/Turning off the Engine for Driving
141
Starting the Engine from the Driver's Cab
143
CHECKLIST: Starting the Engine
143
CHECKLIST: at Low Temperatures
146
Ladders and Access Ladders
146
Refuelling
150
Inspections before Starting the Engine
153
Switch on the Ignition
154
Lamp Test/Equalisation of the Switching States
155
Display - Setting the Brightness
157
Start the Engine
158
Inspections after Starting the Engine
161
Monitoring Elements
164
Monitoring Submenu
165
Setting the Idling Speed
166
Starting/Turning off the Engine for Driving
143
Turning off the Engine
167
On the Ignition Lock/With Hand-Held Control/On the Outrigger Control Units
167
Using the Emergency Stop Switches
168
Air Intake Inhibitor
169
5 5 Driving
171
Before Driving
173
CHECKLIST: Checks before On-Road Driving
173
Checking the Condition of the Truck Crane
178
Adjusting the Seats and Steering Column
183
Switching the Suspension On/Off
186
Setting the Tachograph
188
Displaying the Operating Hours
193
Settings/Indications on the Driving Display
194
Driving
173
Operating the Transmission
195
Switching on
195
Switching the Transmission to Neutral Position
196
Selecting the Direction of Travel and Starting Gear
197
Changing the Operating Mode
199
Starting
200
Driving and Changing Gears
202
Changing the Driving Direction
204
Stopping
204
DM and RM Transmission Mode
205
On the Roller Type Dynamometer
208
Preheating Transmission
208
Driving and Turning off the Truck Crane
209
Checks While Driving
209
Cruise Control
212
Cruise Control
213
Driving Downhill
214
Driving Uphill
218
Warning Submenu
219
Warning or Malfunction Messages on the Instrument Panel
222
Overriding Torque Reduction
224
Errors Submenu
225
Turning off the Truck Crane
225
Folding Berth
228
Off-Road Driving
229
Longitudinal and Transverse Differential Locks
230
Operating the Level Adjustment System
232
Freeing Truck Crane Stuck in Terrain
236
Separate Steering
238
Switching to Separate Steering
238
Heating and Air-Conditioning System
242
Standard Heating System
242
Air-Conditioning System
245
Auxiliary Water Heater
247
Towing a Trailer
254
6 6 Driving Modes and Rigging for On-Road Driving
261
Driving Modes and Rigging for On-Road Driving
263
Driving Modes
263
Information on How to Use the Tables
264
Tables for a Maximum Axle Load of 12 T (26 500 Lbs)
265
Maximum Permitted Speeds with an Axle Load of over 12 T (26 500 Lbs)
267
Rigging Work for Driving with a Trailer
268
Switching on the Slewing Gear Freewheel
269
Switching on Boom Floating Position
270
Switching on Boom Pre-Tensioning
271
Switching the Superstructure Driving Lights On/Off
272
Removing/Installing Main Boom
273
CHECKLIST: Removing the Main Boom
275
CHECKLIST: Installing the Main Boom
277
Slinging the Main Boom
280
Retracting/Fitting the Derricking Cylinder Head Pin
283
Retracting/Extending the Boom Pivot Pin
286
Disconnecting/Connecting Hydraulics/Electrical
289
Lifting the Main Boom Off/On the Turntable
291
Aligning the Connecting Points
293
Securing/Releasing the Derricking Cylinder
293
Transporting the Main Boom
294
Inspections after Main Boom Mounting
295
Installing/Removing Outrigger Beams
297
CHECKLIST: Removing the Outrigger Beams
298
CHECKLIST: Installing the Outrigger Beams
300
Preparing the Truck Crane
302
Removing/Attaching Outrigger Pads
303
Disconnecting/Establishing the Hydraulic Connection
305
Establishing/Disconnecting the Electrical Connection
306
Unscrewing/Screwing in the Spacers
307
Disconnecting/Establishing the Connections to the Outrigger Box
309
Extending/Retracting the Outrigger Beam
309
Transporting the Outrigger Beams
313
Installing/Removing the Supporting Box
315
CHECKLIST: Removing the Supporting Box
316
CHECKLIST: Installing the Supporting Box
319
Rigging the Outrigger Span 7.98 X 8.50/1.00 M (26.1 X 27.9/3.3 Ft)
321
Establishing/Disconnecting the Pneumatic Connection
324
Establishing/Disconnecting the Electrical Connection
325
Disconnecting/Establishing the Hydraulic Connection
326
Attaching/Raising the Supporting Box with the Truck Crane
327
Installing the Reverse Camera
330
Crane Movements During Installation and Removal
331
Slinging Points on the Supporting Box
332
Fixing/Releasing the Outrigger Pins
333
Transporting the Supporting Box on the Separate Vehicle
335
7 7 Malfunctions in Driving Mode
337
Emergency Stop Switch
339
Malfunctions in Driving Mode
339
What to Do When a Malfunction Occurs in Road Traffic
341
Towing the Truck Crane
343
Towing after Engine/Transmission Damage
344
Starting to Tow
347
Other Emergency Operations
349
Externally Starting the Truck Crane
349
Battery Charger
349
Wheels and Tyres
351
Wheel Change
351
Inflating the Tyres Yourself
355
Fuses
357
Fuses in the Driver's Cab
358
Fuses in the Battery Box
363
Troubleshooting
365
Malfunctions in the Engine
365
Malfunctions in the DEF System
367
Malfunctions in the Transmission
368
Malfunctions in the Hydraulic Drive (Megadrive)
368
Service Brake Malfunctions
369
Steering Malfunctions
370
Differential Lock Malfunctions
371
Malfunctions in the Hydraulic System/Hydraulic Oil Cooler
371
Malfunctions on the Suspension
372
Malfunctions on the Level Adjustment System
372
Malfunctions on the ECOS Carrier
373
Procedure During Malfunctions
377
Switching on Emergency Operation in Coolant Circuit
377
Procedure During Engine Malfunctions
378
Procedure During Transmission Malfunctions
379
9 9 Operating Elements for Crane Operation
433
Operating Elements for Crane Operation
435
Overview of the Operating Elements
435
Exterior of the Truck Crane
436
Crane Cab
438
Front Panel
439
Side Panel
441
Control Panels
448
Control Lever Configuration
450
ECOS Control Unit
452
ECOS Display - Main Menu
454
ECOS Display - Submenus
457
RCL Control Unit
472
RCL Display - Main Menu
474
RCL Display - Submenus
475
Hand-Held Controls
483
Outrigger Control Units
486
Short Description of the Operating Elements
491
Definition of Direction References
491
General Rules for Buttons and Symbols on the Display
492
Engine
493
Seat Contact Switch and Dead Man's Switch
495
ECOS Crane Control
496
Outriggers
499
Inclination Indicators
504
Raise Axle
505
Outrigger Pressure Displays
507
Anemometer Display
507
Main Hoist
508
Auxiliary Hoist
510
Slewing Gear
511
Derricking Gear
513
Telescoping Mechanism
515
Hydraulic System
522
Superstructure Lock/Houselock Submenu
523
Rated Capacity Limiter (RCL)
525
Electrical System
539
Lighting, Windscreen Wiper/Washing System
539
Hand-Held Control
542
Windows, Doors, Keys
546
10 10 Starting/Turning off the Engine - for Crane Operation
549
Starting/Turning off the Engine - for Crane Operation
551
When Starting the Engine for the First Time of the Day
551
Refuelling
552
Checks before Starting the Engine
553
Switching on the Ignition
554
Lamp Test/Switching State Equalisation
555
Adjusting Display Brightness
557
Start the Engine
558
Checks after Starting the Engine
560
Monitoring Submenu
561
Setting the Idling Speed
562
Switching off Economy Mode
563
Overriding Torque Reduction
564
Starting the Engine - with the Hand-Held Control
565
Turning off the Engine
567
During Normal Operation, with the Ignition Lock/With the Hand-Held Control
567
In Emergencies, with the Emergency Stop Switches
568
11 11 Crane Operation
569
Before Operating the Crane
571
CHECKLIST: Checks before Operating the Crane
571
Checking the Condition of the Truck Crane
575
Adjusting the Crane Cab Seat and Front Control Panel
577
Checking the Safety Equipment
579
Earthing the Load
582
Locking/Unlocking the Superstructure
583
Switching the Houselock On/Off
585
Crane Operation
571
Operation of the Rated Capacity Limiter
589
Switching on the RCL
590
Entering the Rigging Mode
593
Checks before Operating the Crane
601
Displays During Crane Operation
604
RCL Early Warning
607
RCL Shutdown
607
Display During Errors
609
RCL Override
610
Displaying the Lifting Capacity Tables
619
Entering the Time/Date
621
Crane Operation with Main Boom
623
Checks During Crane Operation
623
Permissible Slewing Ranges and Working Positions
625
Main Hoist
626
Auxiliary Hoist
629
Lifting Limit Switch and Lowering Limit Switch
632
Derricking Gear
634
Telescoping Mechanism
638
High-Speed Mode
666
Slewing Gear
668
Possible Movement Combinations
673
Hydraulic Oil Cooling
674
Settings and Displays for Crane Operation
675
Inclining the Crane Cab
675
Setting Idling Speed
676
Adjusting the Wiper Stroke Interval of the Windscreen Wiper
676
Limiting the Power Unit Speeds
677
Setting the Characteristic Curves for the Control Levers
678
Using the Slewable Spotlights
679
Displaying the Operating Hours
680
Warning Submenu
681
Errors Submenu
684
Working Range Limiter
685
Opening the Working Range Limiter Submenu
686
Viewing Current Settings
686
Entering Limit Values
688
Entering Limit Values/Objects Manually
694
Switching Monitoring Functions On/Off
696
Shutdown by Working Range Limiter
697
Work Break
698
In Case of Short Work Breaks
698
In Case of Work Breaks of more than 8 Hours
699
Heating and Air-Conditioning System
700
Standard Heating System
700
Air-Conditioning System
702
Auxiliary Water Heater
704
Auxiliary Air Heater
711
Cranestar System
713
Overview
713
Position of the Components
713
12 12 Rigging Work
715
Rigging Work
717
Rigging Work Checklists for Crane Operation with the Main Boom
717
CHECKLIST: Rigging
717
CHECKLIST: Unrigging
721
Choosing a Suitable Site
725
Determining the Required Ground Bearing Area
725
Safe Distance from Slopes and Pits
728
Earthing the Truck Crane
729
Safe Distance from Electrical Cables
730
Rigging Work after Driving with a Trailer
733
Switching off the Boom Floating Position
733
Switching off the Slewing Gear Freewheel
734
Switching off Boom Pre-Tensioning
735
Connecting/Disconnecting the Hand-Held Control
737
Starting the Engine for Driving for Rigging Work
739
Starting/Turning off the Engine with the Hand-Held Control
739
Starting/Turning off the Engine from the Crane Cab
741
Starting/Turning off the Engine from the Outrigger Control Units
743
Outriggers
745
CHECKLIST: Extending the Outriggers
745
CHECKLIST: Retracting the Outriggers
747
Permissible Outrigger Spans
748
Preparing the Truck Crane
749
Setting the Outrigger Spans
750
Extending/Retracting Outrigger Beams
753
Moving the Outrigger Pads into Working/Driving Position
759
Enlarging the Ground Bearing Area
760
Extending/Retracting Supporting Cylinders
761
Levelling the Truck Crane on Outriggers
766
Levelling the Free-Standing Truck Crane
771
Outrigger Pressure Display
773
12.7 Rigging/Unrigging the Counterweight
776
Counterweight Sections
776
Identification
776
Slinging Points on the Counterweight Sections
777
CHECKLIST: Counterweight, Rigging
778
CHECKLIST: Counterweight, Unrigging
781
Assembling Counterweight Combination
783
Securing/Releasing 10 T Blocks
795
Establishing/Disconnecting the Hydraulic Connection
797
Making/Breaking the Electrical Connection
798
Rigging Counterweight
799
Raising and Lowering 10 T Counterweight Blocks with a Mounted Auxiliary Hoist
804
Slewing with Rigged Counterweight
805
Rigging the Auxiliary Hoist
807
Identification
807
Slinging Points and Transport
808
CHECKLIST: Mounting the Auxiliary Hoist
810
CHECKLIST: Removing the Auxiliary Hoist
812
Lifting the Auxiliary Hoist Onto the 15 T Base Plate
814
Raising/Setting down the Catcher
815
Establishing/Disconnecting the Hydraulic Connection
816
Making/Breaking the Electrical Connection
817
Locking/Unlocking the Auxiliary Hoist
818
Checking the Auxiliary Hoist for Correct Functioning
821
Securing the Upper Hook Block in the Catcher
822
Railings on the Auxiliary Hoist
822
Permissible Applications for the Auxiliary Hoist
823
Rigging Work on the Main Boom
825
Hook Block on the Bumper
825
Hook Block on a Separate Vehicle
827
Reeving and Unreeving the Hoist Rope
830
Possible Reeving Methods on the Main Boom
835
Installing/Removing the Lifting Limit Switch
842
Locking/Unlocking the Lifting Limit Switch
847
Anemometer and Air Traffic Control Light
848
Other Rigging Work
851
Railings on the Turntable
851
Cameras for Crane Operation
852
13 13 Driving with Rigged Truck Crane
855
Driving Path
857
Driving with Rigged Truck Crane
857
Permissible Rigging Modes and Axle Loads
858
Before Driving
860
Securing the Superstructure against Slewing
860
Checking Tyre Pressure and Wind Speed
861
Putting the Truck Crane on the Wheels
862
Transmission/Connections
864
While Driving
864
After Driving
866
14 14 Malfunctions During Crane Operation
867
Malfunctions During Crane Operation
869
Emergency Stop Switch
869
What to Do When a Malfunction Occurs During Crane Operation
871
Fuses
873
Fuses on the Turntable
874
Fuses in the Crane Cab
877
RCL Fuses
879
Troubleshooting
880
Malfunctions on the Engine
880
Malfunctions on the Main Hoist/Auxiliary Hoist
881
Malfunctions in the Hoist Cameras
882
Malfunctions in the Main Boom Camera
882
Malfunctions in the Derricking Gear
883
Malfunctions in the Slewing Gear
887
Malfunctions in the Hydraulic System/Hydraulic Oil Cooler
888
Malfunctions When Inclining the Crane Cab
888
Malfunctions When Operating with the Hand-Held Control
888
Malfunctions on the Outriggers
889
Troubleshooting on the RCL
890
Malfunctions ECOS - Superstructure
899
Malfunctions on the Cranestar System
902
Emergency Operations and Programmes
907
Mechanical Emergency Activation for Retracting
908
Telescoping Emergency Programme
911
Entering the Current Telescoping
921
Emergency Operation with the Hand-Held Control
923
Hydraulic Emergency Operation
927
Functionality
927
Connecting/Disconnecting Hoses
928
Switching Emergency Operation On/Off
930
Establishing the Required Hydraulic Circuits
931
Performing Emergency Operation
933
After Emergency Operation
935
Emergency Supply of Another Crane
936
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Manitowoc GROVE GMK 6400 Specifications
General
Brand
Manitowoc
Model
GROVE GMK 6400
Category
Construction Equipment
Language
English
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