Manitowoc GROVE GMK 6400 Manuals

Manuals and User Guides for Manitowoc GROVE GMK 6400. We have 2 Manitowoc GROVE GMK 6400 manuals available for free PDF download: Operating Manual, Maintenance Manual

Manitowoc GROVE GMK 6400 Operating Manual (960 pages)

Part 1 - Driving

Brand: Manitowoc | Category: Construction Equipment | Size: 49.58 MB

1 1 Overview

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
- Documentation Supplied
  
  47
  - Questions on Documentation
    48
- Notes on the Operating Instructions
  
  49
- 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
- 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
- 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
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
- Procedure During Malfunctions
  
  377
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
- 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
- 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
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
- 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
- Emergency Operations and Programmes
  
  907
- 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

Manitowoc GROVE GMK 6400 Maintenance Manual (354 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 22.6 MB

Table of Contents

3
6 6 Lubricants and Consumables

61
- Lubricants
  
  63
  - Lubricants List
    64
  - Lubricant Applications List
    65
- Lubricants and Consumables
  
  63
- Consumables
  
  67
  - Fuel
    67
  - Engine Coolant Admixtures
    67
  - After-Treatment of Exhaust Gases
    68
  - Windscreen Washing System Admixtures
    68
  - Fuel for Crane Cab Heating System
    68
- Refrigerant
  
  67
7 7 Maintenance Work on the Carrier

69
- General Instructions
  
  73
- Symbols for Maintenance Work
  
  83
  - Checking the Oil Level
    85
- Engine
  
  85
  - Topping up the Oil
    87
  - Installing the Drain Valve
    88
  - Checking the Air Filter
    89
  - Checking the Coolant Level
    90
  - General Inspection
    91
  - Have the Radiator Checked/Cleaned
    92
  - Changing the Oil and Oil Filter
    96
- Fuel System
  
  99
  - Draining Water from Fuel Filter 1
    100
  - Changing Fuel Filter 1
    101
  - Changing Fuel Filter 2
    103
- Exhaust System with Exhaust Emission Control
  
  107
- Transmission
  
  113
  - General Inspection
    114
  - Checking the Transmission Oil Level
    115
  - Checking the Oil Level - Power Take-Off
    116
  - Changing the Oil and Oil Filter - Transmission
    117
  - Changing the Oil and Oil Filter - Power Take-Off
    121
  - Test Drive
    124
  - Checking the Oil Level
    125
  - General Inspection
    125
- Transfer Case
  
  125
  - Changing the Oil
    126
- Axle Lines
  
  129
- Wheels
  
  141
  - Checking the Tyre Pressure
    142
  - Checking the Tightness of Wheel Nuts
    143
  - Changing the Wheels
    144
  - Checking the Brake Lining Thickness
    149
- Vehicle Brake
  
  149
- Suspension
  
  151
- Steering
  
  155
  - Pressure Accumulator - Checking the Gas Pressure
    156
- Compressed Air System
  
  157
- Hydraulic System
  
  161
  - Checking for Leaks
    162
  - Checking the Hydraulic Hoses
    162
  - Cleaning the Magnetic Rods
    163
  - Changing the Ventilation Filters
    165
  - Taking Oil Samples
    166
  - Changing the Hydraulic Oil
    171
  - Changing the Hydraulic Oil Filter
    175
- Central Lubrication System
  
  179
- Electrical System
  
  183
- Air-Conditioning System
  
  191
  - Checking Hoses
    191
  - Checking the Air Conditioning System
    191
  - Checking the Entire Air-Conditioning System
    192
  - Cleaning the Condenser Fins
    192
  - Changing the Pollen Filter
    194
  - Lubricating the Towbar Coupling
    195
- Towbar Coupling
  
  195
- Other Maintenance Work
  
  203
8 8 Maintenance Work on the Superstructure

211
- General Instructions
  
  213
  - Covers
    213
- Maintenance Work on the Superstructure
  
  213
  - Overview of Maintenance Work on the Superstructure
    214
- Symbols for Maintenance Work
  
  221
  - Checking the Oil Level
    223
- Hoists
  
  223
  - Checking the Hoist Brake
    224
  - General Inspection
    224
  - Support for Block - Checking the Sheaves
    225
  - Changing the Oil/Checking the Oil
    226
  - Having a General Inspection Carried out
    228
  - Having a Partial Inspection Carried out
    228
  - Checking the Oil Level
    229
- Slewing Gear
  
  229
  - Checking for Leaks
    230
  - Checking the Slewing Gear Brake
    230
  - Changing the Oil/Checking the Oil
    232
  - Checking the Bolts
    235
- Slewing Bearing
  
  235
  - Lubricating the Gear Teeth
    239
  - General Inspection
    241
  - Measuring Tilting Play
    242
  - Lubricating the Turntable Lock
    244
  - Checking the Oil Filter
    247
  - General Inspection
    247
- Pump Transfer Case
  
  247
  - Checking the Oil Level
    248
  - Changing the Oil
    249
  - Changing the Oil Filter
    253
  - Checking the Oil Level
    255
- Hydraulic System
  
  255
  - Checking the Hydraulic Hoses
    256
  - Checking the Ventilation Filters
    256
  - Checking for Leaks
    257
  - Cleaning the Magnetic Rods
    258
  - Changing the Ventilation Filters
    261
  - Taking Oil Samples
    263
  - Changing the Hydraulic Oil Filter
    265
  - Changing the Hydraulic Oil
    269
  - Have the Radiator Checked/Cleaned
    272
  - Greasing the Piston Rod of the Derricking Cylinder
    277
- Main Boom
  
  277
  - Lubricating the Telescopic Sections
    278
  - Checking the Locking System
    282
  - Checking the Sheaves
    282
  - Checking the Winding
    283
- Hoist Ropes
  
  283
  - Checking the Hoist Ropes
    284
  - Lubricating the Hoist Rope
    285
  - Assessing the Condition of the Hoist Rope
    286
  - Replacing the Hoist Rope
    292
  - Setting the Lowering Limit Switch
    295
- Cable Drums and Slewing Angle Sensor
  
  297
  - Maintenance of the Slip Ring Assemblies
    298
  - Lubricating the Slewing Angle Sensor
    299
- Central Lubrication System
  
  301
  - Checking the Filling Level
    301
  - Checking the Sheaves
    303
- Hook Blocks
  
  303
  - Lubricating
    303
  - Checking the Lighting and Indicators
    307
- Electrical System
  
  307
- Air-Conditioning System
  
  309
- Other Maintenance Work
  
  311
  - Checking the Functioning of the Auxiliary Heater
    313
  - Lubricating the Crane Cab Door
    314
  - Lubricating the Step
    315
  - Lubricating the Connecting Pins and Socket Pins
    316
  - Renewing the Corrosion Protection
    317
  - Having the Fire Extinguisher Checked
    319
    
    Longer out of Service Periods
    323
  - Torques
    327
  - Spare Parts Required for Maintenance
    331
    
    General Information
    331
    
    Lighting
    331
    
    Spare Parts for the Carrier
    335
    
    Spare Parts for the Superstructure
    338
- Appendix
  
  343

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Manitowoc GROVE GMK 6400 Manuals

Manitowoc GROVE GMK 6400 Operating Manual (960 pages)

Table of Contents

1 1 Overview

Overview

Accidents

Branch Offices

Warranty Specifications

Terms Used

Technical Data

Documentation Supplied

Notes on the Operating Instructions

Conversion Table for US Measuring Units

Training - Information

Identification

EC Declaration of Conformity

2 2 Basic Safety Instructions

3 3 Operating Elements for Driving

Operating Elements for Driving

Overview of the Operating Elements

Short Description of the Operating Elements

4 4 Starting/Turning off the Engine for Driving

Starting the Engine from the Driver's Cab

Starting/Turning off the Engine for Driving

Turning off the Engine

Air Intake Inhibitor

5 5 Driving

Before Driving

Driving

Operating the Transmission

Driving and Turning off the Truck Crane

Off-Road Driving

Separate Steering

Heating and Air-Conditioning System

Towing a Trailer

6 6 Driving Modes and Rigging for On-Road Driving

Driving Modes and Rigging for On-Road Driving

Driving Modes

Rigging Work for Driving with a Trailer

Removing/Installing Main Boom

Installing/Removing Outrigger Beams

Installing/Removing the Supporting Box

7 7 Malfunctions in Driving Mode

Emergency Stop Switch

Malfunctions in Driving Mode

What to Do When a Malfunction Occurs in Road Traffic

Towing the Truck Crane

Other Emergency Operations

Wheels and Tyres

Fuses

Troubleshooting

Procedure During Malfunctions

9 9 Operating Elements for Crane Operation

Operating Elements for Crane Operation

Overview of the Operating Elements

Short Description of the Operating Elements

10 10 Starting/Turning off the Engine - for Crane Operation

Starting/Turning off the Engine - for Crane Operation

When Starting the Engine for the First Time of the Day

Starting the Engine - with the Hand-Held Control

Turning off the Engine

11 11 Crane Operation

Before Operating the Crane

Crane Operation

Operation of the Rated Capacity Limiter

Crane Operation with Main Boom

Settings and Displays for Crane Operation

Working Range Limiter

Work Break

Heating and Air-Conditioning System

Cranestar System

12 12 Rigging Work

Rigging Work

Rigging Work Checklists for Crane Operation with the Main Boom

Choosing a Suitable Site

Rigging Work after Driving with a Trailer

Connecting/Disconnecting the Hand-Held Control

Starting the Engine for Driving for Rigging Work

Outriggers

12.7 Rigging/Unrigging the Counterweight