Grove GMK 6300 Operating Instructions Manual Part 1 (Carrier) – PDF DOWNLOAD
DESCRIPTION:
Grove GMK 6300 Operating Instructions Manual Part 1 (Carrier) – PDF DOWNLOAD
Serial Number : 2 084 548 en
Overview and contents of truck crane user information :
1.3.1 Operating Instructions
These operating instructions contain information required to operate the truck crane.
- In chapter 2 you will find Basic safety instructions. Please read and observe these instructions, even if you are familiar with the safety manual. These Basic safety instructions are in this chapter only; special safety instructions which indicate concrete dangers are contained in the text. There the action related to the danger is described.
- Chapter 3 contains Information for applications engineering. It is intended primarily for the truck crane operator and those responsible for applications engineering. This chapter contains
- Chapters 4 to 6 contain information required for driving the truck crane: a description of all structural and operational components, clearly defined check lists for rigging modes and work, and the operating instructions for on-road and off-road driving.
- In chapter 7 there is information on Troubleshooting for the carrier of the truck crane.
- Chapter 8 includes the Technical description of the individual parts and functional elements of the carrier as well as its Technical data.
- Chapter 9 contains the alphabetical index at the end of part 1 – carrier.
- Chapters 10 to 12 contain information required for Operating the crane section, i.e. work with the truck crane: a description of all components and control elements, information about operating the crane engine as well as the crane itself.
Maintenance manual:
The maintenance manual is intended for maintenance personnel.
The maintenance manual does not contain information on repair work.
The maintenance manual consists of
– instructions for cleaning the truck crane,
– run-in instructions,
– inspection and servicing intervals,
– maintenance tables,
– specifications for the required lubricants and fuels and
– a description of the maintenance work on both the vehicle section and
crane section.
TABLE OF CONTENTS:
Grove GMK 6300 Operating Instructions Manual Part 1 (Carrier) – PDF DOWNLOAD
GMK 6300..................................................................................................................... 1 Operating Instructions Part 1 Carrier.................................................................................... 1 1 Overview........................................................................................................... 5 1.1 Vehicle identification....................................................................................... 7 1.2 EC declaration of conformity................................................................................. 10 1.3 Overview and contents of truck crane user information........................................................ 11 1.3.1 Operating Instructions................................................................................. 11 1.3.2 Lattice extension operating manual (additional equipment).............................................. 12 1.3.3 Maintenance manual..................................................................................... 12 1.3.4 Lifting capacity table................................................................................. 12 1.3.5 Outrigger load table................................................................................... 13 1.3.6 Safety manual.......................................................................................... 13 1.3.7 Spare parts list....................................................................................... 13 1.3.8 Circuit diagrams....................................................................................... 13 1.4 Instructions for use of this document........................................................................ 14 1.4.1 How are the operating instructions laid out?........................................................... 14 1.4.2 How are the pages of the operating manual formatted?................................................... 15 1.4.3 How can I find the necessary information quickly and easily?........................................... 16 1.4.4 Definition of direction information.................................................................... 22 2 Fundamental safety instructions for crane operators................................................................ 23 2.1 Warnings and symbols......................................................................................... 25 2.2 Proper use................................................................................................... 26 2.3 Organisational measures...................................................................................... 28 2.4 Personnel qualifications..................................................................................... 30 2.5 Safety instructions that apply to truck crane driving........................................................ 31 2.6 Safety instructions for truck crane work..................................................................... 31 3 Information for applications engineering........................................................................... 33 3.1 Safety instructions.......................................................................................... 35 3.1.1 Proper use............................................................................................. 35 3.1.2 Organizational measures................................................................................ 35 3.1.3 Personnel qualifications............................................................................... 36 3.2 Applications engineering..................................................................................... 37 3.2.1 Application engineering requirements................................................................... 37 3.2.2 Details about applications engineering contained in the user information............................... 38 4 Description of the truck crane – vehicle section................................................................... 39 4.1 Overview of the operating and display instruments............................................................ 41 4.1.1 Overview of the vehicle................................................................................ 41 4.1.2 Overview of driver’s cab............................................................................... 44 4.1.3 Front instrument panel................................................................................. 48 4.1.4 Side instrument panel.................................................................................. 56 4.2 Functional description of the display and operating instruments.............................................. 62 4.2.1 Instrument panels...................................................................................... 62 4.2.2 Other operating instruments in the vehicle section..................................................... 80 5 Vehicle engine..................................................................................................... 85 5.1 Starting / turning off vehicle engine........................................................................ 87 5.1.1 CHECK LIST: Starting vehicle engine.................................................................... 87 5.1.2 CHECKLIST: In winter................................................................................... 89 5.1.3 Checks before starting up vehicle engine............................................................... 90 5.1.4 Starting vehicle engine................................................................................ 96 5.1.5 Inspections after the engine has been started.......................................................... 99 5.1.6 Turning off the vehicle engine.........................................................................103 6 Driving the truck crane............................................................................................105 6.1 Checking the truck crane before driving......................................................................107 6.1.1 CHECK LIST: Condition of the truck crane for on-road driving...........................................107 6.1.2 Driving mode...........................................................................................111 6.1.3 Checks to be carried out before driving................................................................113 6.2 General operation............................................................................................123 6.2.1 Operating the automatic gearbox........................................................................123 6.2.2 Monitoring the control instruments while driving.......................................................128 6.2.3 Driving on downhill slopes.............................................................................132 6.2.4 Driving on uphill slopes...............................................................................134 6.2.5 Cruise control.........................................................................................134 6.2.6 Turning off the truck crane............................................................................137 6.2.7 Removing/putting on outrigger pads.....................................................................139 6.3 Off-the-road driving.........................................................................................141 6.3.1 Off-the-road gear......................................................................................142 6.3.2 Drive of the second axle line / longitudinal differential locks........................................143 6.3.3 Transverse differential locks in all driven axle lines.................................................145 6.4 Separate steering............................................................................................151 6.4.1 Switching on separate steering.........................................................................152 6.4.2 Steering axle lines with separate steering.............................................................153 6.4.3 Switching off separate steering and locking steering...................................................154 6.4.4 Matching steering angle................................................................................156 6.5 Heating and ventilation......................................................................................157 6.5.1 Driver’s cab heating system............................................................................157 6.5.2 Roof blower (additional equipment).....................................................................159 6.5.3 Additional water heating system (additional equipment).................................................160 6.5.4 Additional heating system with timer (additional equipment)............................................162 6.6 Air-conditioning system (additional equipment)...............................................................165 6.6.1 Switching on...........................................................................................165 6.6.2 Switching off..........................................................................................165 6.6.3 Air conditioning.......................................................................................166 6.7 Towing a trailer (additional equipment)......................................................................169 7 Malfunctions on the carrier........................................................................................175 7.1 Emergency stop device on carrier.............................................................................177 7.2 Breakdown in road traffic....................................................................................179 7.3 Towing the truck crane.......................................................................................181 7.4 Wheel change.................................................................................................187 7.5 Electrical system............................................................................................191 7.5.1 Plug-in modules........................................................................................191 7.5.2 Fuses..................................................................................................193 7.6 Troubleshooting and malfunction correction...................................................................197 7.6.1 Vehicle engine malfunctions............................................................................197 7.6.2 Automatic gearbox malfunctions.........................................................................199 7.6.3 Transfer case malfunctions.............................................................................200 7.6.4 Differential lock malfunctions.........................................................................201 7.6.5 Service brake malfunctions.............................................................................202 7.6.6 Steering system malfunctions...........................................................................202 7.6.7 Outrigger malfunctions.................................................................................203 7.6.8 Suspension locking system malfunctions.................................................................204 7.6.9 Level adjustment system malfunctions...................................................................204 7.7 Procedure in the event of malfunctions.......................................................................205 7.7.1 Switching the fan thermostat to emergency operation....................................................205 7.7.2 Troubleshooting for malfunctions in the automatic gearbox..............................................206 7.7.3 Emergency operation of the solenoid valves for the outriggers..........................................207 7.8 Separate steering emergency operation........................................................................211 8 Technical specifications carrier...................................................................................215 8.1 Technical description of the carrier.........................................................................217 8.1.1 Crane carrier..........................................................................................217 8.1.2 Driver’s cab...........................................................................................217 8.1.3 Drive units............................................................................................218 8.1.4 Engine and gearbox cooling system......................................................................218 8.1.5 Hydraulic system.......................................................................................218 8.1.6 Steering...............................................................................................219 8.1.7 Suspension system......................................................................................219 8.1.8 Outrigger..............................................................................................220 8.1.9 Compressed air system..................................................................................220 8.1.10 Service brake.........................................................................................221 8.1.11 Parking brake.........................................................................................221 8.1.12 Retarder..............................................................................................221 8.1.13 Secondary consumers...................................................................................221 8.1.14 Towing the crane......................................................................................222 8.1.15 Towing a trailer......................................................................................222 8.1.16 Electrical system.....................................................................................222 8.1.17 Slewing duct..........................................................................................222 8.2 Technical specifications.....................................................................................223 8.2.1 Measurements and weights of the truck crane............................................................224 8.2.2 Dimensions and weights of removable parts..............................................................225 8.2.3 Carrier technical data.................................................................................226 9 Alphabetical index.................................................................................................231 Operating Instructions Part 2 Superstructure.............................................................................249 10 Description of the truck crane – crane section....................................................................253 10.1 Overview of the operating and display instruments...........................................................255 10.1.1 Overview of crane section.............................................................................255 10.1.2 Crane cab overview....................................................................................258 10.1.3 Instrument panel......................................................................................260 10.1.4 Left control console..................................................................................274 10.1.5 Right control console.................................................................................275 10.1.6 Control box for operating the outriggers..............................................................276 10.1.7 Counterweight lifting gear switch unit................................................................277 10.1.8 Electronic level control box..........................................................................278 10.2 Functional description of the display and operating instruments.............................................279 10.2.1 Crane work............................................................................................279 10.2.2 Other operating instruments on the crane cab..........................................................310 10.3 Functional description of the safety devices................................................................313 10.3.1 Safe load indicator (SLI).............................................................................313 10.3.2 Lowering limit switch.................................................................................314 10.3.3 Lifting limit switch..................................................................................315 11 Crane engine......................................................................................................317 11.1 Starting/turning off the crane engine.......................................................................319 11.1.1 CHECK LIST: Starting the crane engine.................................................................319 11.1.2 CHECKLIST: In winter..................................................................................321 11.1.3 Inspections before starting the crane engine..........................................................322 11.1.4 Starting the crane engine.............................................................................328 11.1.5 Inspections after starting crane engine...............................................................332 11.1.6 Switch off the crane engine...........................................................................333 12 Crane operation...................................................................................................335 12.1 Checking the truck crane before working with the crane......................................................337 12.1.1 CHECK LIST: When truck crane is rigged................................................................337 12.1.2 Preheating the hydraulic oil..........................................................................341 12.1.3 Mechanical superstructure lock........................................................................342 12.1.4 Electrical system.....................................................................................343 12.1.5 Check the position of the hoist ropes.................................................................344 12.1.6 Adjusting the mirrors.................................................................................344 12.1.7 Visual inspection of the entire crane.................................................................345 12.1.8 Checking the reservoir of the windscreen washing system...............................................345 12.1.9 Checking the safety devices...........................................................................346 12.2 Operating the safe load indicator...........................................................................349 12.2.1 Switching on the SLI..................................................................................349 12.2.2 Setting rigging mode..................................................................................352 12.2.3 Checks before working with the crane..................................................................359 12.2.4 During crane work.....................................................................................361 12.3 Crane work with the main boom...............................................................................367 12.3.1 External influences during crane operation............................................................367 12.3.2 Slewing ranges permitted for working with the crane...................................................371 12.3.3 Hoists................................................................................................372 12.3.4 Derricking gear.......................................................................................377 12.3.5 Slewing gear..........................................................................................379 12.3.6 Telescoping gear......................................................................................383 12.3.7 Fast speed............................................................................................414 12.3.8 Menus on the crane control display....................................................................415 12.3.9 Setting a constant engine speed.......................................................................425 12.3.10 Critical load control................................................................................426 12.3.11 Incline crane cab....................................................................................427 12.3.12 Cooling the hydraulic oil............................................................................428 12.3.13 Possible movement combinations.......................................................................428 12.4 Driving with a rigged crane.................................................................................429 12.4.1 Driving route.........................................................................................429 12.4.2 Position of the boom..................................................................................430 12.4.3 Driving the rigged truck crane........................................................................432 12.5 Work break..................................................................................................435 12.5.1 Short work break......................................................................................435 12.5.2 Work breaks lasting more than 8 hours.................................................................436 12.6 Crane cab heating and ventilation...........................................................................437 12.6.1 Heating the crane cab.................................................................................437 12.6.2 Additional water heating system (additional equipment)................................................438 12.6.3 Additional heating system with timer (additional equipment)...........................................439 12.6.4 Ventilating the crane cab.............................................................................440 12.7 Air-conditioning system (additional equipment)..............................................................441 12.7.1 Switching on..........................................................................................441 12.7.2 Switching off.........................................................................................441 12.7.3 Air conditioning......................................................................................442 13 Rigging work......................................................................................................445 13.1 Check lists for rigging work for crane operation with main boom.............................................447 13.1.1 CHECK LIST: Rigging...................................................................................447 13.1.2 CHECK LIST: Unrigging.................................................................................450 13.2 Choosing a suitable site....................................................................................453 13.2.1 Load bearing capacity of the ground and the outrigger.................................................453 13.2.2 Safe distance from banks and pits.....................................................................456 13.2.3 Safe distance from electrical lines...................................................................456 13.2.4 Earthing the truck crane..............................................................................457 13.3 Outrigger...................................................................................................459 13.3.1 CHECK LIST: Extending the outriggers..................................................................459 13.3.2 CHECK LIST: Retracting outrigger......................................................................461 13.3.3 Outrigger span........................................................................................463 13.3.4 Preparing the outriggers..............................................................................466 13.3.5 Extending / retracting the outrigger beams............................................................469 13.3.6 Moving the outrigger pads into working / driving position.............................................474 13.3.7 Extending / retracting the outrigger cylinders........................................................476 13.4 Counterweight...............................................................................................483 13.4.1 Counterweight sections and identification.............................................................483 13.4.2 Counterweight versions................................................................................484 13.4.3 Slinging points on the counterweight sections.........................................................487 13.4.4 CHECKLIST: Rigging the counterweight..................................................................488 13.4.5 CHECKLIST: Unrigging the counterweight................................................................491 13.4.6 Placing the 8 t base plate............................................................................494 13.4.7 Prepare the 8 t base plate............................................................................496 13.4.8 Assembling the counterweight version..................................................................499 13.4.9 Extending/retracting the lifting cylinders of the 8 t base plate or lifting/lowering counterweight....502 13.4.10 Locking the counterweight on the turntable/releasing the locking pin.................................505 13.4.11 Slewing with the counterweight rigged................................................................507 13.5 Rigging work on the main boom...............................................................................509 13.5.1 Hook block on the bumper..............................................................................509 13.5.2 Hook block on a separate vehicle......................................................................511 13.5.3 Reeving and unreeving the hoist rope..................................................................513 13.5.4 Possible reeving methods on the main boom.............................................................521 13.5.5 Anemometer............................................................................................525 14 Auxiliary hoist assembly/disassembly..............................................................................529 14.1 CHECKLISTS: Mounting/dismounting with auxiliary crane.......................................................531 14.1.1 CHECKLIST: Mounting with auxiliary crane..............................................................531 14.1.2 CHECKLIST: Dismounting with auxiliary crane...........................................................534 14.2 CHECKLISTS: Mounting/dismounting with counterweight lifting gear............................................537 14.2.1 CHECKLIST: Mounting with counterweight lifting gear...................................................537 14.2.2 CHECKLIST: Removal with counterweight lifting gear....................................................540 14.3 Rigging work during mounting/dismounting....................................................................543 14.3.1 Slinging points and transport.........................................................................543 14.3.2 Attaching and reeving the guy unit....................................................................546 14.3.3 Lift auxiliary hoist to the main hoist with auxiliary crane...........................................549 14.3.4 Locking the auxiliary hoist / releasing lock..........................................................550 14.3.5 Establishing/disconnecting the hydraulic connection...................................................551 14.3.6 Establishing/disconnecting electrical connection......................................................552 14.3.7 Lifting/lowering the auxiliary hoist with the counterweight...........................................553 14.3.8 Checking that the auxiliary hoist is functioning properly.............................................556 14.3.9 Transport protection for the upper sheave.............................................................557 14.3.10 Permitted utilization options for the auxiliary hoist................................................558 15 Malfunctions on the superstructure................................................................................563 15.1 Superstructure emergency stop device........................................................................563 15.2 Troubleshooting for malfunctions that occur during crane operation..........................................565 15.3 Electrical system...........................................................................................567 15.3.1 Plug-in modules and consoles..........................................................................567 15.3.2 Fuses.................................................................................................569 15.3.3 SLI fuses.............................................................................................575 15.4 Troubleshooting and malfunction correction..................................................................577 15.4.1 Crane engine malfunctions.............................................................................577 15.4.2 Main hoist malfunctions...............................................................................579 15.4.3 Auxiliary hoist malfunctions..........................................................................581 15.4.4 Derricking gear malfunctions..........................................................................583 15.4.5 Telescoping gear malfunctions.........................................................................584 15.4.6 Slewing gear malfunctions.............................................................................587 15.4.7 Counterweight lifting gear / lock malfunctions........................................................588 15.4.8 Hydraulic system / hydraulic oil cooler malfunctions..................................................589 15.4.9 Crane control malfunctions............................................................................590 15.4.10 Malfunctions on the SLI..............................................................................591 15.4.11 Retraction emergency operation.......................................................................606 15.4.12 Switching the fan thermostat to emergency operation..................................................622 15.5 Crane control error messages................................................................................623 15.5.1 Error messages about control units....................................................................623 15.5.2 Error messages about power units......................................................................624 15.5.3 Telescoping error messages............................................................................629 15.5.4 Changing the connections in the control units.........................................................630 15.5.5 Control lever emergency program.......................................................................634 15.5.6 Emergency operation submenu...........................................................................636 15.5.7 Entering telescope status after emergency operation menu..............................................642 16 Technical information for superstructure..........................................................................647 16.1 Technical description of the superstructure.................................................................647 16.1.1 Turntable.............................................................................................647 16.1.2 Crane operator’s cab..................................................................................647 16.1.3 Crane engine and hydraulic system.....................................................................648 16.1.4 Control system........................................................................................649 16.1.5 Main boom.............................................................................................649 16.1.6 Telescoping gear......................................................................................649 16.1.7 Hoists................................................................................................650 16.1.8 Slewing gear units....................................................................................650 16.1.9 Derricking cylinder...................................................................................651 16.1.10 Electrical system....................................................................................651 16.1.11 Counterweight........................................................................................651 16.1.12 Safety equipment.....................................................................................652 16.2 Technical data..............................................................................................653 16.2.1 Measurements and weights of the truck crane...........................................................654 16.2.2 Dimensions and weights of removable parts.............................................................655 16.2.3 Technical data for superstructure.....................................................................659 17 Alphabetical index................................................................................................663
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