Page 1 Maintenance manual 3 302 364 en 25.11.2016...
Page 2 Important note Any type of duplication or excerpt from this document, even in electronic form, is not subject to the revision service of Manitowoc Crane Group Germany GmbH © Copyright reserved by Manitowoc Crane Group Germany GmbH Industriegelände West D-26389 Wilhelmshaven, Germany...
Page 3 Customer service If the local maintenance personnel discover any damage then trained engineers customer service engineers from Manitowoc Crane Care or an authorised GROVE dealer must be requested to perform repairs on the telescoping à Note – Having the telescoping cylinder and check the entire locking system;...
Page 4 Blank page 3 302 584 en Additional pages for maintenance manual GMK 4100L-1...
Page 5 Main boom M 12 1.2.1 Check/lubricate the telescoping cylinder • Consult the Maintenance manual supplied for information on prerequisites, and observe the safety instructions outlined in Chapter Main boom . • Familiarise yourself with the slinging points for personal safety à...
Page 6 Maximum value: 10 bar (145 psi) Minimum value: 9 bar (131 psi) • Have the filling pressure checked and if necessary corrected by Manitowoc Crane Care or an authorised GROVE dealer. 3 302 584 en Additional pages for maintenance manual GMK 4100L-1...
Page 7 Head – variants Two different variants of the head can be fitted depending on the truck crane equipment. Type (A) – The connecting link (1) slides on the head (2) on metal surfaces. Type (B) – The connecting link (1) slides on the head (2) over six plastic wear pads (3).
Page 8 Cleaning • Clean the head (3) with a clean cloth. • Clean the running surfaces of the connecting link (1) and the guides and joints of the lever (2). • Check all moving parts and running paths for damage. • Check the sensor electrical connectors for damage.
Page 9 (1) and (2) using a feeler gauge (3). If the gap dimensions are too large or too small • Have the head repaired by Manitowoc Crane Care or an authorised à Note – Having the telescoping cylinder repaired , p. 1 - 9.
Page 10 You will need to put the truck crane out of service if malfunctions occur in the telescoping system. • Have any damage repaired immediately by Manitowoc Crane Care or an authorised GROVE dealer. 3 302 584 en Additional pages for maintenance manual...
Page 11 The supplied maintenance manual GMK 4100L-1 already specifies that you must have the locking system on the main boom inspected annually (M12) by Manitowoc Crane Care or an authorised GROVE dealer. Especially the head of the telescoping cylinder is checked and adjusted during this annual maintenance work.
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Page 13 Transmission – shorter maintenance intervals Engine-transmission unit – overview GMK4100L-1, GMK5150, GMK5150L Engine-transmission unit – Diesel engine type OM 470 (1), – Transmission (2), – Water retarder SWR (3); are the rear of the transmission (additional equipment); SWR = Secondary Water Retarder. Transmission The automatic transmission has 16 speeds and the type designation G 280-16.
Page 14 Shorter maintenance intervals • Maintenance Perform the maintenance work as described in the maintenance manual information supplied. • Also observe the shorter maintenance intervals; à Transmission oil change , à Replace coolant . 1.2.1 Transmission oil change • Change the oil every three years (Y 3). Y 2/3 1.2.2 Replace coolant...
Page 15 Slewing angle sensor Version (A) and (B) Depending on the type of truck crane, a slewing angle sensor of type (A) or (B) can be installed on the slewing bearing. Version (A) For this version, the specifications in the supplied maintenance manual apply. Version (B) Deviating from the specifications in the maintenance manual supplied, this version of the slewing angle sensor is maintenance-free.
Page 16 Blank page 3 302 704 en Additional page GMK truck cranes...
Page 17 If you discover any damage • Have the defective rope attachment point re- placed by or an au- Manitowoc Crane Care thorised GROVE dealer. Additional pages for maintenance manual 3 302 809 en GMK truck cranes...
Page 18 Blank page 3 302 809 en Additional pages for maintenance manual GMK truck cranes...
Page 19: Table Of Contents
Contents: General instructions Safety and environmental protection Cleaning Run-in regulations Maintenance overview Lubricants and consumables Maintenance work on the carrier Maintenance work on the superstructure Longer out of service periods 10 Torques 11 Spare parts required for maintenance Appendix This maintenance manual does not replace the operating manual. Details of operation and standard safety instructions can be found in the operating instructions.
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Page 21 General instructions Instructions for using the maintenance manual......1 - Warnings and symbols ..........1 - Maintenance instructions .
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Page 23: General Instructions
General instructions 1.1 Instructions for using the maintenance manual General instructions Instructions for using the maintenance manual This maintenance manual is not designed to replace proper training and instructions. Maintenance personnel for this truck crane must have the relevant, specialist knowledge and that of proper safety procedures. Please read Chapters 1 and 2 carefully before beginning maintenance work.
Page 24: Maintenance Instructions
It is your responsibility to maintain and service the truck crane regularly and carefully in order to extend its service life and keep it in good working order. Please note that Manitowoc Crane Group Germany GmbH can only uphold the warranty provided for the truck crane if the following conditions are met: –...
Page 25 Do not put off maintenance work that is due. If repairs are needed, immediately contact or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care This work may only be carried out by trained, qualified personnel. A few general maintenance instructions: •...
Page 26: Instructions Regarding The Electronic Controls
Manitowoc Crane Care All welding work (especially on load carrying members) may only be performed by qualified professional personnel with the prior written permission from Manitowoc Crane Group Germany GmbH. 1 - 4 3 302 364 en Maintenance manual...
Page 27: Definition Of Direction References
General instructions 1.6 Definition of direction references Definition of direction references Basic rule Direction information always depends on whether the carrier or the superstructure is being operated. On the carrier The driver's cab is always at the front, which means that: 1: front 2: right 3: rear...
Page 28 General instructions 1.7 Conversion table for US measuring units Conversion table for US measuring units The following conversion factors will help you convert from metric to US units when the truck crane is used in countries that use US units of measurement and vice versa.
Page 29 Safety and environmental protection Safety rules ............2 - 2.1.1 Securing against unauthorised use .
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Page 31: Safety And Environmental Protection
Safety and environmental protection 2.1 Safety rules Safety and environmental protection Safety rules When carrying out maintenance work, please observe the applicable accident prevention regulations. Observe the following safety rules: • Familiarise yourself with the truck crane and its operation. Read the operating manual carefully and request guidance from the crane operator •...
Page 32 Safety and environmental protection 2.1 Safety rules If due to exceptional circumstances the truck crane needs be put into operation for certain types of maintenance work, great care must be taken where there are moving parts (superstructure, outriggers, Cardan shafts, slewing bearing, engines, tiltable crane cab).
Page 33: Securing Against Unauthorised Use
Safety and environmental protection 2.1 Safety rules 2.1.1 Securing against unauthorised use • Secure the truck crane against unauthorised use by: – Applying the parking brake, – Switching the transmission to position N, – Turning off the engine, – Removing the ignition key and –...
Page 34: Handling Substances Which Are Harmful To The Environment
Safety and environmental protection 2.2 Handling substances which are harmful to the environment Handling substances which are harmful to the environment Which substances When you carry out maintenance work on the truck crane you will are harmful to the occasionally work with consumables which are classified as harmful environment? to the environment by applicable national and regional regulations.
Page 35 Safety and environmental protection 2.2 Handling substances which are harmful to the environment Separate collec- Substances which are harmful to the environment should always tion and storage be collected separately from other waste. • Ask your local environmental protection authority about the different categories of the substances.
Page 36: Disposal Of The Truck Crane
Before you decide to finally decommission your truck crane and scrap it: • Allow to advise you about alternatives. Manitowoc Crane Care • Proper disposal Find out about the applicable official regulations regarding the final de- registration and disposal at the place of registration of the truck crane.
Page 37 Cleaning Overview of assemblies easily damaged when cleaning ....3 - Maintenance manual 3 302 364 en GMK 4100L-1...
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Page 39: Cleaning
Cleaning Cleaning During the first The paintwork on the truck crane will continue to harden for the first 3 months three months. • During this period the crane may be cleaned only with cold water. • Do not use high-pressure or steam jet cleaning equipment during this period.
Page 40 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Overview of assemblies easily damaged when cleaning 3 - 2 3 302 364 en Maintenance manual GMK 4100L-1...
Page 41 Cleaning 3.1 Overview of assemblies easily damaged when cleaning 1 Electrical connections on the boom head 2 Telescopic slide faces 3 Angle data transmitter 4 Lowering limit switch 5 Steering computer 6 Suspension struts 7 Slewing angle sensor 8 Heating/air conditioning system under the crane cab 9 Control units for outriggers 10 Steering angle sensor 11 Carrier electronic control equipment...
Page 42 Cleaning 3.1 Overview of assemblies easily damaged when cleaning Blank page 3 - 4 3 302 364 en Maintenance manual GMK 4100L-1...
Page 43 Run-in regulations Maintenance manual 3 302 364 en GMK 4100L-1...
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Page 45: Run-In Regulations
Run-in regulations Run-in regulations There are regulations about running in individual parts which must be followed, after: – First commissioning or – Replacement of a part or – General overhaul. This is why you must carry out additional maintenance work on the carrier and superstructure after specific periods of time have expired: Operating Driven km...
Page 46 Run-in regulations Operating hours (oper. hrs.) Additional maintenance work on the SUPERSTRUCTURE after 50 Tighten the clips on the coolant hoses; à Special torques , p. 10 - 2. during the first 100 Check the hydraulic oil filter every week, and change it if necessary;...
Page 47 Maintenance overview Maintenance intervals..........5 - Maintenance plans .
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Page 49: Maintenance Overview
Maintenance overview 5.1 Maintenance intervals Maintenance overview – Maintenance plans D (= daily), – Maintenance plans W (= weekly) and – Maintenance plans M 1 (= once a month) to M 12 (= every 12 months) and – Maintenance plans Y 2 (= every 24 months) to Y 10 (= every 120 months). The maintenance plans are given in table form, divided into –...
Page 50 Maintenance overview 5.1 Maintenance intervals The maintenance interval which occurs first determines when the next maintenance is due. – The driven km (or mi) can be taken from the speedometer. – You can individually call up the Operating hours (oper. hrs.) of the engine and power units on the CCS display.
Page 51 Maintenance overview 5.2 Maintenance plans Maintenance plans The descriptions of specific maintenance work in the maintenance plans D, W, M 1 to M 12 and Y 2 to Y 10 have been provided for – the carrier in Chapter 7 and for –...
Page 52 Maintenance overview 5.2 Maintenance plans 5.2.1 Maintenance plan D Maintenance work on the CARRIER: Daily/before putting into operation Engine à – Checking the oil level p. 7 - 13 à – Checking the air filter p. 7 - 16 à –...
Page 53 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Daily/before putting into operation Hydraulic system à – Checking the oil level p. 8 - 31 Hoist ropes à – Checking the winding p. 8 - 51 Electrical system à –...
Page 54 Maintenance overview 5.2 Maintenance plans 5.2.2 Maintenance plan W Maintenance work on the CARRIER: Weekly Engine à – General inspection p. 7 - 18 Transmission à – General inspection p. 7 - 40 Transfer case à – General inspection p. 7 - 45 Angle gear à...
Page 55 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Weekly Hoists à – Checking the oil level p. 8 - 9 à – General inspection p. 8 - 10 à – Checking the hoist brake p. 8 - 10 Slewing gear à...
Page 56 Maintenance overview 5.2 Maintenance plans 5.2.3 Maintenance plan M 1 Maintenance work on the CARRIER: monthly/after approx. 2,000 km (approx. 1,240 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 Exhaust system with exhaust emission control à...
Page 57 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: Monthly/after approx. 100 operating hours Main boom à – Greasing the piston rod of the derricking cylinder p. 8 - 45 Air conditioning system à – Checking the air conditioning system p.
Page 58 Maintenance overview 5.2 Maintenance plans 5.2.4 Maintenance plan M 3 Maintenance work on the CARRIER: every three months/after 5,000 – 6,000 km (3,100 – 3,730 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 Fuel system à...
Page 59 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: every three months/after 250 oper. hrs. Slewing bearing à – Checking the screws p. 8 - 21 Hydraulic system à – Cleaning the magnetic rods p. 8 - 34 Main boom à...
Page 60 Maintenance overview 5.2 Maintenance plans 5.2.5 Maintenance plan M 6 Maintenance work on the CARRIER: every six months/after 10,000 – 12,500 km ( 6,210 – 7,770 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 Transfer case à...
Page 61 Maintenance overview 5.2 Maintenance plans Maintenance work on the SUPERSTRUCTURE: every six months/after 500 oper. hrs. Slewing gear à – Checking the slewing gear brake p. 8 - 16 Slewing bearing à – Lubricating the gear teeth p. 8 - 25 à...
Page 62 Maintenance overview 5.2 Maintenance plans M 12 5.2.6 Maintenance plan M 12 Maintenance work on the CARRIER: every 12 months/after 20,000 – 25,000 km ( 12,430 – 15,530 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 à...
Page 63 Maintenance overview 5.2 Maintenance plans M 12 Maintenance work on the SUPERSTRUCTURE: every 12 months/after 1,000 oper. hrs. Hoists à – Changing the oil/checking the oil p. 8 - 11 Slewing gear à – Changing the oil/checking the oil p. 8 - 19 Slewing bearing à...
Page 64 Maintenance overview 5.2 Maintenance plans 5.2.7 Maintenance plan Y 2 Maintenance work on the CARRIER: every 24 months/after 40,000 – 50,000 km ( 25,000 – 31,000 mi) Engine à à Engine manufacturer’s documentation – Notes; p. 7 - 13 à –...
Page 65 Maintenance work on the CARRIER: every 60 months/100,000 km (62,000 mi) – Have the Cardan shaft between the transmission on the engine and the transfer case replaced by or an authorised GROVE Manitowoc Crane Care dealer. Transmission à – Changing the oil p.
Page 66 Maintenance work on the CARRIER: every 120 months/after 200,000 km (124,000 mi) Steel construction – Check the load-bearing steel construction. For further information, please contact Manitowoc Crane Care Maintenance work on the SUPERSTRUCTURE: every 120 months/after 12,000 oper. hrs. Electrical system à...
Page 67 Maintenance overview 5.3 Periodic inspections Periodic inspections Your GMK 4100L-1 truck crane has been inspected before delivery. – Truck cranes used in Germany are inspected in accordance with the regulations of the professional trade association as defined by BGV D 6 (VBG 9). –...
Page 68 Maintenance overview 5.3 Periodic inspections 5.3.1 Load hook inspection The hook opening on the load hooks must be checked regularly for deformation. The hook opening must not have increased by more than 10% of the original dimension y, y1, y2. The original dimensions y, y1, y2 are specified in field (2) on the load hooks.
Page 69 Maintenance overview 5.4 Measures required for winch monitoring Measures required for winch monitoring Also observe the information on the general inspection of the hoists; à p. 8 - 13. These measures for monitoring the winches (hoists) were compiled by the German Machine Builders' Association (VDMA) and are to be used for all truck cranes according to the German Accident Prevention Regulations for Winches, Hoists and Tractor Machines, BGV D 6 (VGB 9 ) and BGV D 8 (VBG 8) .
Page 70 Maintenance overview 5.4 Measures required for winch monitoring The actual service life of a winch is affected by a number of additional external factors, such as: 1. Overloading caused by improper use of the truck crane. 2. Insufficient maintenance: Oil is not changed at the specified intervals.
Page 71 Maintenance overview 5.4 Measures required for winch monitoring Determining the The truck crane's load spectrum is divided into groups (see also ISO 4301/1, operating FEM 1.001): conditions (load spectrum) When determining the load spectrum, the existing rope pull is used as the standard, i.e.
Page 72 Maintenance overview 5.4 Measures required for winch monitoring One of the load spectrums listed above should be selected on the basis of the actual operating conditions and entered in the crane logbook for the respective testing interval. Note for truck cranes: The load spectrum L1 and the load spectrum factor Km = 0.125 are generally applied to truck cranes in assembly mode.
Page 73 Maintenance overview 5.4 Measures required for winch monitoring The general overhaul is to be arranged by the operator and performed by the manufacturer or a representative authorised by the manufacturer. The results are to be entered in the crane logbook. The manufacturer or an authorised representative will specify a new theoretical service life D upon completion of the general overhaul.
Page 74 5.4 Measures required for winch monitoring 5.4.3 Example A GMK 4100L-1 is equipped with a separate operating hours counter for the hoist and is classified by Manitowoc Crane Group Germany GmbH as follows: Power unit group: Load spectrum: light L1, Km = 0.125...
Page 75 Maintenance overview 5.4 Measures required for winch monitoring The used proportion S of theoretical service life after the second inspection is therefore:  -------------- - 480 h 1,920 h 0,125 Remaining theoretical service life: D2 = 3,040 h -1,920 h = 1,120 h. The above values are entered in the table (see table example p.
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Page 77 Lubricants and consumables Lubricants............6 - 6.1.1 Lubricants list .
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Page 79: Lubricants And Consumables
Lubricants and consumables 6.1 Lubricants Lubricants and consumables Lubricants All lubricants that you require for – Maintenance work on the carrier , p. 7 - 1 and – Maintenance work on the superstructure , p. 8 - 1 are listed with serial numbers in the lubricants list and the lubricant applications list.
Page 80: Lubricants List
Lubricants and consumables 6.1 Lubricants 6.1.1 Lubricants list Consec. GROVE- Lubricant Designation Specification Viscosity Part type according to classification number DIN 51502 MIL-L 2104 C 03329588 Engine oil HD - CD SAE 5 W-30 DB 228.5 Fuchs Titan Cytrac MB Synth 04162042 Gear oil SAE 75 W-90...
Page 81: Lubricant Applications List
Lubricants and consumables 6.1 Lubricants 6.1.2 Lubricant applications list Consec. Lubricant Usage Fill Mainte- type quantity nance in litres interval (gal) à Engine oil Diesel engine; p. 7 - 25 34 (9.0) à Gear oil Transmission; p. 7 - 42 15.5 (4.1) à...
Page 82 Lubricants and consumables 6.1 Lubricants Consec. Lubricant Usage Fill Mainte- type quantity nance in litres interval (gal) à Carrier central lubrication; p. 7 - 115 à Superstructure central lubrication; p. 8 - 69 à Cardan shafts – transverse; p. 7 - 64 à...
Page 83: Refrigerant
Lubricants and consumables 6.2 Refrigerant Refrigerant Refrigerant designation Usage Fill quantity Maintenance in kg (lbs) interval Air conditioning system à in the driver's cab; p. 7 - 128 1.0 (2.2) M 12 (Compressor oil: FUCHS SE 55) Tetrafluoroethane (R134a) CAS no. 811-97-2 1 x 1.0 (2.2) Air conditioning system EC no.
Page 84: Exhaust Gas Emission Control
Lubricants and consumables 6.3 Consumables 6.3.3 Exhaust gas emission control Designation Usage Fill quantity in litres (gal) DEF (Diesel Exhaust Fluid) à AdBlue: AdBlue tank on the carrier; p. 7 - 34 40 (10.5) GROVE part number: 03140555 DEF (Diesel Exhaust Fluid), Consumable for exhaust gas emission control, e.g.
Page 85 Maintenance work on the carrier General instructions ..........7 - 7.1.1 Covers .
Page 86 7.10 Wheels ............7 - 67 7.10.1 Checking the tyres for damage .
Page 87 7.18.5 Changing the pollen filter ......... . . 7 - 130 7.19 Towbar coupling .
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Page 89: Maintenance Work On The Carrier
Maintenance work on the carrier 7.1 General instructions Maintenance work on the carrier General instructions The truck crane GMK 4100L-1 is fitted as standard with an AdBlue system for exhaust gas emission control. In this case an AdBlue tank (1) à...
Page 90: Tilting And Lowering The Driver's Cab
Maintenance work on the carrier 7.1 General instructions 7.1.2 Tilting and lowering the driver's cab • Check whether the truck crane GMK 4100L-1 is fitted with driver's cab that can be tilted (additional equipment). A driver's cab that can be tilted makes it easier to access the front of the motor and maintenance work can be performed more conveniently.
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Page 92: Overview Of Maintenance Work On The Carrier
Maintenance work on the carrier 7.1 General instructions 7.1.3 Overview of maintenance work on the carrier 7 - 4 3 302 364 en Maintenance manual GMK 4100L-1...
Page 93 Maintenance work on the carrier 7.1 General instructions à Symbols for maintenance work p. 7 - 11 à 1 CCS (Crane Control System) control unit p. 7 - 11 à Engine p. 7 - 13 à 5 Diesel engine p. 7 - 13 à...
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Page 95 Maintenance work on the carrier 7.1 General instructions à Axle lines p. 7 - 55 à 7 Axle centre drives p. 7 - 55 à 6 Final drives p. 7 - 61 à 8 Cardan shafts p. 7 - 64 à...
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Page 97 Maintenance work on the carrier 7.1 General instructions à Wheels p. 7 - 67 à 5 Wheels p. 7 - 67 3 Spare wheel (alternatively storage box) à Suspension p. 7 - 83 à 8 Suspension struts p. 7 - 85 à...
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Page 99: Symbols For Maintenance Work
Maintenance work on the carrier 7.2 Symbols for maintenance work Symbols for maintenance work • Check the symbols on the CCS start menu (Crane Control System) in the driver's cab each day before starting work. • The Start menu shows the most important measurements and the Maintenance submenu shows all the outstanding warning messages;...
Page 100 Maintenance work on the carrier 7.2 Symbols for maintenance work Blank page 7 - 12 3 302 364 en Maintenance manual GMK 4100L-1...
Page 101: Engine
Maintenance work on the carrier 7.3 Engine Engine • In addition, carry out further maintenance work specified in the Engine manufacturer’s documentation supplied. 7.3.1 Checking the oil level Prerequisites – The truck crane must be level. à • Operating Instructions . Checking the Start the engine from the driver's cab;...
Page 102 Maintenance work on the carrier 7.3 Engine • On the dipstick (1), check that the oil level is between the min. and the max. marks (arrow markings). • After checking the oil level, put the dipstick back in the dipstick tube. If the oil level is too low à...
Page 103: Topping Up The Oil
Maintenance work on the carrier 7.3 Engine 7.3.2 Topping up the oil à Data on the prescribed oil specification; Engine manufacturer’s documentation . Engine oil Designation Specification GROVE part no. in litres (gal) to DIN 51502 classification 34 (9.0) HD - CD MIL-L 2104 C SAE 5 W-30 DB 228.5...
Page 104: Checking The Air Filter
Maintenance work on the carrier 7.3 Engine 7.3.3 Checking the air filter • Start the engine and monitor the display. • If the symbol (1) is displayed, you must change the air filter. • Switch the engine off. Spare parts Designation Quantity GROVE part no.
Page 105: Checking The Coolant Level
Risk of damage to engine due to lack of coolant. If the coolant has to be topped up frequently, the cooling system may be leaking. Have the cooling system checked by or an Manitowoc Crane Care authorised GROVE dealer or your repair crew. Maintenance manual 3 302 364 en...
Page 106: General Inspection
Checking the coolant level , p. 7 - 17. • Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. M 12 7.3.6 Have the radiator checked/cleaned •...
Page 107 Maintenance work on the carrier 7.3 Engine Check the level of dirt The radiator units (1), (2) and (3) are protected by grilles (4) and plates (5). The fan impellers (6) are located under the grilles. When the engine is running, the fan impeller rotates under the grille! Risk of injury at the fan impeller! When the fan impeller is rotating it can trap the fingers of your hand and...
Page 108 Maintenance work on the carrier 7.3 Engine Radiator unit 1 The radiator unit 1 consists of: – Radiator for water/charge air engine, – Cooler for the transmission gear oil. – Cooler for the transfer case gear oil. – Cooling coil for compressed air, –...
Page 109 Maintenance work on the carrier 7.3 Engine • • Have the radiator units (1), (2) and (3) opened up by the repair crew so that the radiator fins are accessible. • Have the radiator fins cleaned on both sides, using suitable cleaning agents.
Page 110 Maintenance work on the carrier 7.3 Engine • After checking/ Remove all tools and cleaning equipment. cleaning • Check that the grille (4) and enclosure plates (5) are secure. • Start the engine and wait until the fan impellers are rotating. •...
Page 111: Checking The V-Belt Tension
Maintenance work on the carrier 7.3 Engine M 12 7.3.7 Checking the V-belt tension à Comply also with the Run-in regulations , p. 4 - 1. • Check whether your truck crane is fitted with a second alternator (2) (additional equipment). Maintenance of the V-belt of the first alternator (1) fitted as standard à...
Page 112 Maintenance work on the carrier 7.3 Engine • Familiarise yourself with the correct operation of the frequency à Separate engine operating instructions, provided by measuring instrument; the manufacturer . • Switch the frequency measuring instrument (1) on – it is now ready for acoustic measurement.
Page 113: Changing The Oil And Oil Filter
Maintenance work on the carrier 7.3 Engine 7.3.8 Changing the oil and oil filter Oil, spare parts, Engine oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502 classification 34 (9.0) HD - CD MIL-L 2104 C SAE 5 W-30 DB 228.5 03329588...
Page 114 Maintenance work on the carrier 7.3 Engine Oil filter • Place a receptacle underneath the engine. • Change the oil filter (1) using a socket wrench – torque 55 Nm (40.5 lbf ft); à Engine manufacturer’s documentation . • Leave the receptacle in place for the oil change.
Page 115: Fuel System
Operating Instructions . • Obtain information from on the additional fuel Manitowoc Crane Care filter required for the dual tank system. The following elements are installed as standard in the carrier fuel line: 1 Fuel filter 1 (large)
Page 116: Draining Off Water From Fuel Filter 1
Maintenance work on the carrier 7.4 Fuel system 7.4.1 Draining off water from fuel filter 1 à Spare parts – Receptacle, approx. 5 ltr (1.5 gal); p. 2 - 4. and tools à Operating Instructions . Prerequisites – The truck crane must be level and on outriggers; à...
Page 117: Replacing Fuel Filter 1
Maintenance work on the carrier 7.4 Fuel system 7.4.2 Replacing fuel filter 1 Spare parts and Designation Quantity GROVE part no. tools Filter (large) 04161991 à – Receptacle, approx. 5 ltr (1.5 gal); p. 2 - 4. – Torque wrench for a torque of 55 Nm (40.5 lbf ft). à...
Page 118 Maintenance work on the carrier 7.4 Fuel system • Remove the cover (1). • Remove the old filter (2) from the casing. • Place the old filter (2) in the receptacle. • Insert a new filter (2) into the casing. •...
Page 119: Replacing Fuel Filter 2
Maintenance work on the carrier 7.4 Fuel system M 12 7.4.3 Replacing fuel filter 2 Spare parts Designation Quantity GROVE part no. and tools Filter (small) 04161566 à – Receptacle, approx. 5 ltr (1.5 gal); p. 2 - 4. – Torque wrench for a torque of 15 Nm (11 lbf ft). à...
Page 120 Maintenance work on the carrier 7.4 Fuel system • Open the two tank covers on the fuel tank; à p. 7 - 27. • Operate the hand pump (1) until you sense definite resistance. • Close the two tank covers on the fuel tank. •...
Page 121: Exhaust System With Exhaust Emission Control
Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control Exhaust system with exhaust emission control Overview To comply with the exhaust emission regulations, the truck crane may only be run with the exhaust system with SCR catalytic converter (SCR = Selective Catalytic Reduction).
Page 122: Checking The Adblue Tank Level
Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control 7.5.1 Checking the AdBlue tank level Checking The display includes a gauge showing the level in the AdBlue tank. The tank has a maximum filling volume of about 40 ltr (10.5 gal). Depending on where the truck crane is used, it may be sensible to carry additional canisters of AdBlue.
Page 123: Check The Exhaust System For External Damage
Maintenance work on the carrier 7.5 Exhaust system with exhaust emission control • Filling up Find out about filling up in the operating manual and note the warnings; à Operating Instructions . Danger of scalding due to ammonia vapours. Ammonia vapour can escape if the AdBlue tank is opened when the outside temperature is high.
Page 124 • Switch the engine off. If you discover any damage Have any damaged parts of the exhaust system replaced immediately by or an authorised GROVE dealer. Manitowoc Crane Care 7 - 36 3 302 364 en Maintenance manual GMK 4100L-1...
Page 125: Having The Adblue System Checked
M 12 7.5.4 Having the AdBlue system checked This inspection may only be performed by Manitowoc Crane Care an authorised GROVE dealer or an authorised specialist workshop. • Have the entire AdBlue system checked for leaks and correct operation; Overview , p. 7 - 33.
Page 126 Oil from the compressed air system can damage the pump unit. Therefore, a filter cartridge must be installed in the compressed air drier that removes both water and oil. recommends the Manitowoc Crane Care suitable filter cartridge with the GROVE part number 04157844. à •...
Page 127: Transmission
Maintenance work on the carrier 7.6 Transmission Transmission Overview Engine-transmission unit – Diesel engine (1), – Transmission (2), – Water retarder SWR (3); are the rear of the transmission (additional equipment); SWR = Secondary Water Retarder. Transmission The automatic transmission has 16 speeds and the type designation G 280-16.
Page 128: General Inspection
The transmission oil cooler is located within the radiator unit 1; à p. 7 - 20. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7 - 40 3 302 364 en Maintenance manual...
Page 129: Checking The Oil Level
Maintenance work on the carrier 7.6 Transmission M 12 7.6.2 Checking the oil level Spare parts and Designation Quantity GROVE part no. tools Gasket 24 x 29 Cu DIN 7603 00117145 à – Receptacle, approx. 5 ltr (1.5 gal); p. 2 - 4. –...
Page 130: Changing The Oil
Maintenance work on the carrier 7.6 Transmission 7.6.3 Changing the oil Oil, spare parts Gear oil Specification GROVE part no. and tools in litres (gal) Classification 15.5 (4.1) Fuchs Titan 04162042 Cytrac MB Synth with oil cooler API-GL-4; SAE 75 W-90 Designation Quantity GROVE part no.
Page 131 Maintenance work on the carrier 7.6 Transmission • Place a receptacle under the screw (2). • Unscrew the screws (1) and (2) and allow the oil to drain off. • Clean the drain plugs. • Replace the gasket and tighten the drain plug (2) –...
Page 132 Maintenance work on the carrier 7.6 Transmission Topping up the oil • Fill the oil up to the lower edge of the opening. • Replace the gasket and tighten the drain plug (1) – torque 25 Nm (18.4 lbf ft). Checks after the oil change After changing oil, check for leakage:...
Page 133: Transfer Case
• Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.7.2 Checking the oil level Spare parts...
Page 134: Changing The Oil
Maintenance work on the carrier 7.7 Transfer case Checking • Remove the drain plug (1). • Check that the oil reaches the lower edge of the opening. • Fit a new gasket and tighten the screw. If the oil level is too low à...
Page 135 Maintenance work on the carrier 7.7 Transfer case Changing the oil Risk of scalding from gear oil at operating temperature. You could scald yourself by gear oil escaping in an uncontrolled manner at operating temperature. Wear appropriate protective gloves and take care not to come into contact with the gear oil.
Page 136 Maintenance work on the carrier 7.7 Transfer case Blank page 7 - 48 3 302 364 en Maintenance manual GMK 4100L-1...
Page 137: Angle Gear
Maintenance work on the carrier 7.8 Angle gear Angle gear à • Comply also with the Run-in regulations , p. 4 - 1. Access The angle gear (1) is located in the travel gear frame at the centre of rotation of the turntable. Within the oil circuit (2) the gear oil for the angle gear (1) is routed via a separate oil cooler (3) and through a separate filter (4).
Page 138: General Inspection
Checking the oil level , p. 7 - 50. • Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.8.2 Checking the oil level Spare parts...
Page 139 Check the secure fastening and the condition of the resilient dampers (1): If the resilient dampers are damaged, have them replaced by or an authorised GROVE dealer. Manitowoc Crane Care Maintenance manual 3 302 364 en 7 - 51 GMK 4100L-1...
Page 140: Changing The Oil And The Oil Filter
Maintenance work on the carrier 7.8 Angle gear 7.8.3 Changing the oil and the oil filter Oil, spare parts, Gear oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502 classification 7.2 (1.9) MIL-L 2105 B 01373344 API-GL-5 for type A Viscosity:...
Page 141 Maintenance work on the carrier 7.8 Angle gear Changing the oil Risk of scalding from gear oil at operating temperature. You could scald yourself by gear oil escaping in an uncontrolled manner at operating temperature. Wear appropriate protective gloves and take care not to come into contact with the gear oil.
Page 142 Maintenance work on the carrier 7.8 Angle gear • Remove the screw (1) from the oil cooler (2). • Fill the oil up to the lower edge of the opening (1). • If necessary fit a new gasket and tighten the screw (1).
Page 143: Axle Lines
Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop. 7.9.2 Axle centre drives – checking the oil level...
Page 144 Maintenance work on the carrier 7.9 Axle lines 1. and 4th axle lines • Remove the drain plug (1). • Check that the oil reaches the lower edge of the opening. • Fit a new gasket and tighten the screw. If the oil level is too low à...
Page 145: Axle Centre Drives - Changing The Oil
Maintenance work on the carrier 7.9 Axle lines 3. axle line The drive has two oil chambers. • Remove the screw (1). • Check that the oil reaches the lower edge of the openings. • Fit a new gasket and tighten the screw. If the oil level is too low à...
Page 146 Maintenance work on the carrier 7.9 Axle lines Prerequisites – The truck crane must be raised on outriggers or parked over an inspection pit. – The engine must be switched off and secured against unauthorised use; à p. 2 - 3. Risk of environmental damage due to leaking consumables.
Page 147 Maintenance work on the carrier 7.9 Axle lines 3rd axle line The drive has two oil chambers. Risk of oil overheating. When topping up the oil, both openings must be opened so that both oil tanks are filled equally. This prevents the oil tanks from being overfilled and thus the oil from overheating.
Page 148 Maintenance work on the carrier 7.9 Axle lines Blank page 7 - 60 3 302 364 en Maintenance manual GMK 4100L-1...
Page 149: Final Drives - Checking The Oil Level
Maintenance work on the carrier 7.9 Axle lines 7.9.4 Final drives – Checking the oil level Spare parts for drive Designation Quantity GROVE part no. and tools 8 x 6 x 8 Gasket 24 x 29 Cu DIN 7603 00117145 8 x 8 x 8 Gasket 24 x 29 Cu DIN 7603 00117145...
Page 150: Final Drives - Changing The Oil
Maintenance work on the carrier 7.9 Axle lines M 12 7.9.5 Final drives – Changing the oil Oil, spare parts, Gear oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502 classification for each final C - LPF MIL-L 2105 B 00552891 drive:...
Page 151 Maintenance work on the carrier 7.9 Axle lines Draining oil • Change the oil on all final drives in the same way. • Turn the wheel until the screw (1) is at the bottom. • Use a drain channel and place a receptacle under the screw.
Page 152: Lubricating The Cardan Shafts In The Axle Lines
Maintenance work on the carrier 7.9 Axle lines 7.9.6 Lubricating the Cardan shafts in the axle lines Check all Cardan shafts to see if they have grease nipples. Cardan shafts with grease nipples must be serviced, Cardan shafts without grease nipples are maintenance-free. Grease, spare Lubricating Designation...
Page 153: Lubricating Longitudinal Cardan Shafts
Maintenance work on the carrier 7.9 Axle lines 7.9.7 Lubricating longitudinal Cardan shafts Check all Cardan shafts to see if they have grease nipples. Cardan shafts with grease nipples must be serviced, Cardan shafts without grease nipples are maintenance-free. Grease, spare Lubricating Designation Specification...
Page 154 Maintenance work on the carrier 7.9 Axle lines Blank page 7 - 66 3 302 364 en Maintenance manual GMK 4100L-1...
Page 155: Wheels
Maintenance work on the carrier 7.10 Wheels 7.10 Wheels 7.10.1 Checking the tyres for damage Prerequisites – The truck crane must be raised on outriggers. – The engine must be switched off and secured against unauthorised use; à p. 2 - 3. –...
Page 156: Checking The Tyre Pressure
Maintenance work on the carrier 7.10 Wheels 7.10.2 Checking the tyre pressure Risk of damage to the tyres. The tyre pressure increases during operation. Never release the increased air pressure of tyres at operating temperature. Always check the tyre pressure in on-road driving mode with cold tyres. •...
Page 157: Checking That The Wheel Nuts Are Tight
Maintenance work on the carrier 7.10 Wheels 7.10.3 Checking that the wheel nuts are tight Spare parts and Designation Quantity GROVE part no. tools per wheel Wheel nut with pressure plate 01207756 for steel rims Wheel nut with pressure plate 7659100000 for aluminium rims –...
Page 158: Changing The Wheels
Maintenance work on the carrier 7.10 Wheels 7.10.4 Changing the wheels The wear on tyres varies depending on whether the axle – is driven/not driven, – is steered/not steered, – is braked/not braked, – and whether it is subject to more or less load. To achieve even wear, you must swap the wheels to different positions regularly.
Page 159 Maintenance work on the carrier 7.10 Wheels Recognising two- piece aluminium rims The round-head bolts (1) are on the outer face of the rim. The round heads must be free of cracks, and the bolts must be seated securely in the bores. Around the edge of the aluminium rim there are impressed marks and safety instructions which must be complied with by the specialist...
Page 160 Maintenance work on the carrier 7.10 Wheels • Mount the wheels on another axle, as shown in the diagram. Replace any à damaged parts. Tighten the wheel nuts; p. 7 - 69. 7 - 72 3 302 364 en Maintenance manual GMK 4100L-1...
Page 161 Maintenance work on the carrier 7.10 Wheels Optimised wheel To ensure even more even wear on all tyres, you can also rotate the tyres changes on the wheel rim and mount them on the other side of the vehicle. Risk of accidents if the procedure is not carried out correctly. This section only shows the sequence to be followed when changing wheels.
Page 162 Maintenance work on the carrier 7.10 Wheels Blank page 7 - 74 3 302 364 en Maintenance manual GMK 4100L-1...
Page 163: Vehicle Brake
Maintenance work on the carrier 7.11 Vehicle brake 7.11 Vehicle brake 7.11.1 Checking the wear display On the brake caliper Each brake caliper (1) carries two brake pads (2), arranged one to the left and one to the right of the brake disc (3). The lining thickness (A) is monitored by an electric wear indicator on the brake caliper (1).
Page 164: Checking Disc Brakes
Maintenance work on the carrier 7.11 Vehicle brake If the symbol (1) is displayed on the on-board computer, one of the disc brakes has exceeded the brake pad wear limit. à • Checking disc brakes , p. 7 - 76. Check all disc brakes on all axle lines;...
Page 165 All repair work on the vehicle brakes may only be performed by or an authorised GROVE dealer or an authorised Manitowoc Crane Care specialist workshop with specially trained repair crew. •...
Page 166 Maintenance work on the carrier 7.11 Vehicle brake Checking the surface • Check for signs of damage such as cracks and irregularities: (A) – fine network of cracks, (B) – radial cracks, (C) – circular irregularities, (D) – continuous cracks. •...
Page 167 Maintenance work on the carrier 7.11 Vehicle brake • Checking the Check the thickness of the brake pads on all axle lines. brake pads Each brake caliper (1) carries two brake pads (2), arranged one to the left and one to the right of the brake disc (3). The first and second axle lines have two brake calipers per brake disc.
Page 168 Maintenance work on the carrier 7.11 Vehicle brake Risk of injury due to rotation of the ring spanner If you are holding the ring spanner when another person in the driver's cab applies the brakes your hand could be crushed. Do not hold the ring spanner when another person in the driver's cab applies the brakes.
Page 169 7 - 77. • All repair work on the vehicle brakes may only be performed by or an authorised GROVE dealer or an authorised Manitowoc Crane Care specialist workshop with specially trained repair crew. à • Spare parts and tools , Make sure that only original spare parts are used;...
Page 170 Maintenance work on the carrier 7.11 Vehicle brake Blank page 7 - 82 3 302 364 en Maintenance manual GMK 4100L-1...
Page 171: Suspension
Notify or an authorised GROVE dealer. Manitowoc Crane Care Risk of damage to the suspension struts due to insufficient lubrication. It is difficult to inject the oil. Even so, do not fill oil through the sight glass connections.
Page 172 • Close the drain plug (4). • Defective suspension struts should be replaced as soon as possible by or an authorised GROVE dealer. Manitowoc Crane Care 7 - 84 3 302 364 en Maintenance manual GMK 4100L-1...
Page 173: Suspension Struts - Checking The Fastening
Maintenance work on the carrier 7.12 Suspension 7.12.2 Suspension struts – checking the fastening Spare parts and – Torque wrench for torques up to 900 Nm (664 lbf ft). tools à Operating Instructions. Prerequisites – The truck crane must be raised on outriggers; –...
Page 174: Forced Lever - Checking Correct Functioning
If the suspension struts are not extended or only partially extended, the forced lever is faulty. • Faulty forced levers should be replaced as soon as possible by or an authorised GROVE dealer or your qualified Manitowoc Crane Care repair crew. 7 - 86 3 302 364 en Maintenance manual...
Page 175: Pressure Accumulator - Checking The Gas Pressure
The filling pressure at 20 °C (68 °F) is 50 bar (725 psi). • Have the filling pressure checked and if necessary corrected by Manitowoc Crane Care or an authorised GROVE dealer or an authorised specialist workshop. Maintenance manual 3 302 364 en...
Page 176 Maintenance work on the carrier 7.12 Suspension Blank page 7 - 88 3 302 364 en Maintenance manual GMK 4100L-1...
Page 177: Steering
Maintenance work on the carrier 7.13 Steering 7.13 Steering 7.13.1 Checking the steering monitoring Checks in the driver's cab • Consult the operating instructions regarding lights and symbols for à Operating Instructions . steering monitoring in the driver's cab; • Start the engine and monitor the display.
Page 178: Checking The Angle Sensors
Check the steering computer and the displays for external damage. If you find damage to the angle sensors or steering computers • Immediately notify or an authorised GROVE dealer. Manitowoc Crane Care 7 - 90 3 302 364 en Maintenance manual GMK 4100L-1...
Page 179: Checking For Leaks
Bleed the hydraulic system; If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. Maintenance manual 3 302 364 en 7 - 91 GMK 4100L-1...
Page 180 Maintenance work on the carrier 7.13 Steering Blank page 7 - 92 3 302 364 en Maintenance manual GMK 4100L-1...
Page 181: Compressed Air System
(1) to (7). If a great deal of water escapes • Have the compressed air drier checked or replaced by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair personnel. Maintenance manual 3 302 364 en 7 - 93...
Page 182: Checking For Leaks
If damage cannot be rectified immediately or further damage is likely: • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. 7 - 94 3 302 364 en Maintenance manual...
Page 183: Replacing The Filter Cartridge Of The Compressed Air Drier
Maintenance work on the carrier 7.14 Compressed air system 7.14.3 Replacing the filter cartridge of the compressed M 12 air drier Spare parts and Designation Quantity GROVE part no. tools Filter cartridge 04157844 – Strap wrench. Prerequisites – The truck crane must be raised on outriggers or parked over an inspection pit.
Page 184 Maintenance work on the carrier 7.14 Compressed air system Blank page 7 - 96 3 302 364 en Maintenance manual GMK 4100L-1...
Page 185: Hydraulic System
Maintenance work on the carrier 7.15 Hydraulic system 7.15 Hydraulic system Risk of environmental damage due to leaking consumables. Always let consumables drain into suitable receptacles. Wipe up any consumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations.
Page 186: Checking The Hydraulic Hoses
Maintenance work on the carrier 7.15 Hydraulic system 7.15.2 Checking the hydraulic hoses Hydraulic hoses are also subject to ageing as well as internal and external strain. • Check the hydraulic hoses for – external damage (tears, abrasion, heat damage, chemical damage), –...
Page 187: Cleaning The Magnetic Rods
Bleed the carrier's hydraulic system; p. 7 - 110. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. 7.15.4 Cleaning the magnetic rods Spare parts Designation Quantity GROVE part no.
Page 188 Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system checked by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. • Assemble the filters (2) and insert them.
Page 189: Changing The Ventilation Filter
Maintenance work on the carrier 7.15 Hydraulic system M 12 7.15.5 Changing the ventilation filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty interval locations – you must change the ventilation filters earlier than normal. Spare parts Designation Quantity...
Page 190: Taking Oil Samples
Maintenance work on the carrier 7.15 Hydraulic system M 12 7.15.6 Taking oil samples • Reducing the Under difficult operating conditions – at tropical or very hot locations – interval you must halve the oil change interval. Spare parts – A hose with a connecting piece for a gauge port. and tools Hose lengths GROVE part no.
Page 191 Maintenance work on the carrier 7.15 Hydraulic system Protecting the hose from dirt Danger of contamination of the oil sample If the hose with the connecting piece is dirty, the dirt can contaminate the oil sample in the sample container during the sampling process. The laboratory analysis would thus be incorrect.
Page 192 Maintenance work on the carrier 7.15 Hydraulic system Taking oil samples The hose end (1) is connected to the cylinder (3). The hose end (2) is in receptacle (4). • Start the engine. • Allow 2 litres (0.5 gal) of oil to flow into the receptacle.
Page 193 Maintenance work on the carrier 7.15 Hydraulic system Dispatch the oil gives you the opportunity to have the oil sample Manitowoc Crane Care sample to the analysed at our contracted laboratory. A delivery note and a protective laboratory mailing bag are available along with the sample containers (GROVE part no.
Page 194 Maintenance work on the carrier 7.15 Hydraulic system Blank page 7 - 106 3 302 364 en Maintenance manual GMK 4100L-1...
Page 195: Changing The Hydraulic Oil
Maintenance work on the carrier 7.15 Hydraulic system 7.15.7 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis indicates the à Determining the quality of the oil , p. 7 - 105. need for it; Oil, spare parts, Hydraulic oil Designation...
Page 196 Maintenance work on the carrier 7.15 Hydraulic system Handling the The valves can only be opened and closed using the connecting piece valves and hose. The connecting piece is available in the toolbox. Risk of environmental damage due to leaking consumables. Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the hydraulic oil.
Page 197 Maintenance work on the carrier 7.15 Hydraulic system Topping up the oil Risk of damage to the hydraulic system Cleanliness is of the utmost importance when handling hydraulic oil. Even fresh hydraulic oil must be filtered before it is added to the tank. •...
Page 198 If the steering system is still not operating properly • Notify or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. 7 - 110 3 302 364 en Maintenance manual GMK 4100L-1...
Page 199: Changing The Hydraulic Oil Filter
Maintenance work on the carrier 7.15 Hydraulic system 7.15.8 Changing the hydraulic oil filter When changing the oil, all the oil filters must be replaced. If a warning message appears, the symbol (1) in the Warning submenu indicates that you must change oil filters 1 and 2. If a warning message appears, the symbol (1) in the Warning submenu indicates that you must change oil filter 3.
Page 200 Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system checked by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. • Assemble the filters (2) and insert them.
Page 201 Maintenance work on the carrier 7.15 Hydraulic system Changing filters 3 and 4 Risk of damage to the environment from filter residues Store used hydraulic oil filter inserts in suitable receptacles and have them disposed of properly by qualified personnel. •...
Page 202 Maintenance work on the carrier 7.15 Hydraulic system Blank page 7 - 114 3 302 364 en Maintenance manual GMK 4100L-1...
Page 203: Central Lubrication System
Maintenance work on the carrier 7.16 Central lubrication system 7.16 Central lubrication system 7.16.1 Checking the level Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease to DIN 51502 classification Grease KP - 1K - 50 DIN 51825 03233369 –...
Page 204 Maintenance work on the carrier 7.16 Central lubrication system Topping up Risk of damage to the central lubrication system. Cleanliness is of the utmost importance when handling grease and filling pumps. Do not remove the caps from the connections and the filling pump until immediately before refilling the grease, as the grease could otherwise become contaminated.
Page 205: Bleeding The Central Lubrication System
Maintenance work on the carrier 7.16 Central lubrication system • Attach the filling pump to the respective connections (1), (2) or (3). • Press the button (4) once. Intermediate lubrication will be triggered. • Fill the grease container up to the max. marking.
Page 206: Triggering Intermediate Lubrication
Maintenance work on the carrier 7.16 Central lubrication system 7.16.3 Triggering intermediate lubrication Intermediate lubrication should be activated: – after high pressure cleaning, – to check the lubrication system at all lubricating points. • Switch on the ignition. • Press the button (1) once. An intermediate lubrication cycle will be triggered which lasts approximately 2 minutes.
Page 207: Electrical System
Risk of accidents if the safety devices are faulty! Have faulty lights and indicators repaired by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. • Check the following functions every day before operating or driving the truck crane, and have faulty parts repaired: –...
Page 208: Checking The Batteries
Maintenance work on the carrier 7.17 Electrical system 7.17.2 Checking the batteries Risk of poisoning from batteries containing lead Battery poles, terminals and parts inside the battery contain lead. Residue containing lead can stick to your hands and may not be allowed to enter your body –...
Page 209 Maintenance work on the carrier 7.17 Electrical system Checking the connecting terminals • Keep the batteries clean and dry. • Remove any dirty connecting terminals (1) and clean them. • Fasten any loose connecting terminals. • Grease the connecting terminals and poles lightly with a special battery terminal grease.
Page 210: Checking The Charge Level Of The Batteries
Maintenance work on the carrier 7.17 Electrical system 7.17.3 Checking the charge level of the batteries à Spare parts – Battery charger (additional equipment); p. 7 - 124; or and tools – Acid siphon. Charge level table The measurement of the acid concentration with the acid siphon will give you an indication of the charge level of the batteries.
Page 211 Maintenance work on the carrier 7.17 Electrical system Before checking • Switch off the battery master switch (1). • Open the cover on the battery box. Checking the acid concentration Batteries without covers (1) are maintenance- free. • Remove all caps (1). •...
Page 212: Charging The Batteries Using The Battery Charger
Maintenance work on the carrier 7.17 Electrical system 7.17.4 Charging the batteries using the battery charger Prerequisites – The engine must be switched off and secured against unauthorised use; à p. 2 - 3. – An external 230 V mains power supply must be available at the location. –...
Page 213: Check The External Starting Socket
Maintenance work on the carrier 7.17 Electrical system 7.17.5 Check the external starting socket The battery box is equipped with an external starting socket (1). Accessories A connection cable (1) for the external starting socket is supplied with the truck crane (tool set). Designation GROVE part no.
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Page 215: Air-Conditioning System
• Do not start it up again to avoid further damage. Have the air-conditioning system repaired as soon as possible by or an authorised GROVE dealer or an authorised Manitowoc Crane Care specialist workshop. 7.18.2 Checking hoses Risk of burns due to escaping refrigerant.
Page 216: Cleaning The Condenser Fins
Checking the entire air-conditioning system This inspection may only be performed by or an Manitowoc Crane Care authorised GROVE dealer or an authorised specialist workshop. Risk of burns due to escaping refrigerant. Wear suitable safety glasses and gloves when checking the hoses and connections.
Page 217 Maintenance work on the carrier 7.18 Air-conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. Tetrafluoroethane (R134a) 811-97-2 1.0 (2.2) 212-377-0 Compressor oil FUCHS SE 65 Filler connections The filler connections (1) for the refrigerant are behind the front flap (2) in the driver's cab.
Page 218: Changing The Pollen Filter
Maintenance work on the carrier 7.18 Air-conditioning system M 12 7.18.5 Changing the pollen filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty interval locations – you must change the filter earlier than normal. Spare parts Designation Quantity GROVE part no.
Page 219: Towbar Coupling
Maintenance work on the carrier 7.19 Towbar coupling 7.19 Towbar coupling Depending on the equipment fitted to your truck crane, it may have towbar couplings (additional equipment) from different manufacturers. The wear values for other manufacturers may vary from those specified; à...
Page 220 Maintenance work on the carrier 7.19 Towbar coupling Closing the towbar coupling Risk of injury when manually closing the towbar coupling When closing, the lever moves down with great force in the direction of the coupling jaw. Start the closing process only by moving the lever briefly in the direction of the coupling jaw with the ball of your hand.
Page 221: Checking The Bearing
Maintenance work on the carrier 7.19 Towbar coupling 7.19.2 Checking the bearing à Prerequisites – The coupling must be closed; p. 7 - 132. Checking the bearing Risk of injury! Ensure that the towbar coupling is closed for the following work (lever points downwards).
Page 222: Checking The Cotter Pin
46.0 mm (1.81 in) If the dimension is smaller than that given above, have the cotter pin replaced by or an authorised GROVE Manitowoc Crane Care dealer or your qualified repair crew. • Also check the cotter pin for the correct vertical play.
Page 223: Checking The Lower Bushing
Model series 700: 34.2 mm (1.35 in) If the dimension is larger than that given above, have the bushing replaced by or an authorised GROVE Manitowoc Crane Care dealer or your specialist repair crew. 7.19.5 Checking the initial tension of the springs The coupling head should require physical force to twist it when checking the torque.
Page 224: Checking The Support Ring
Maintenance work on the carrier 7.19 Towbar coupling 7.19.6 Checking the support ring à Prerequisites – The coupling must be closed; p. 7 - 132. Checking the support ring • Check the support ring (1) at the bottom of the coupling jaw. When the trailer is coupled, the draw eyelet of the trailer must not be in contact with the lower bushing (2).
Page 225 Maintenance work on the carrier 7.19 Towbar coupling Checking for correct functioning The coupling jaw must be able to move easily in both directions. • Hold the coupling jaw (1) pressed slightly to the left or right. • Open the coupling (position A) and let the coupling jaw go.
Page 226 Maintenance work on the carrier 7.19 Towbar coupling Blank page 7 - 138 3 302 364 en Maintenance manual GMK 4100L-1...
Page 227: Other Maintenance Work
Maintenance work on the carrier 7.20 Other maintenance work 7.20 Other maintenance work 7.20.1 Checking the windscreen washing system Water, spare Designation Quantity GROVE part no. parts, tool Wiper blades 04159795 – Water; add commercially available detergent and antifreeze to it. –...
Page 228: Lubricating The Outrigger Beams
Maintenance work on the carrier 7.20 Other maintenance work 7.20.2 Lubricating the outrigger beams à • Comply also with the Run-in regulations , p. 4 - 1. Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease to DIN 51502 classification Grease KP - 1K - 50...
Page 229: Checking The Auxiliary Heater
Check that the system is working properly. Also perform a functional check of the controls. • If the heating system is not working correctly, report it to or an authorised GROVE dealer or an authorised Manitowoc Crane Care specialist workshop. M 12 7.20.4 Lubricating the cab door...
Page 230: Lubricating The Connecting And Socket Pins
Check the pins for wear such as rust, deformation, broken clips, chains and pin-type keepers. • If the pins are damaged, have them replaced by Manitowoc Crane Care or an authorised GROVE dealer or your qualified repair crew. • Use only authentic replacement pins.
Page 231: Renewing The Corrosion Protection
Maintenance work on the carrier 7.20 Other maintenance work M 12 7.20.6 Renewing the corrosion protection Protective agent, Protective agent GROVE part no. tools Corrosion protection 03140192 – Spray gun with spray extension. – Brush. – Protective clothing, protective goggles. Prerequisites –...
Page 232 Maintenance work on the carrier 7.20 Other maintenance work Spraying Risk of injury to the eyes. While working with the spray extension you could be hit by the spray jet or spray droplets. Wear protective goggles, protective clothing and gloves. •...
Page 233: Having The Fire Extinguisher Checked
Maintenance work on the carrier 7.20 Other maintenance work 7.20.7 Having the fire extinguisher checked Depending on your truck crane's equipment, it can be fitted with fire extinguishers. The maintenance interval may even be shorter, depending on the respective national regulations and the operating location. Ask the local fire safety officer about the national and local regulations.
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Page 235 Maintenance work on the superstructure General instructions ..........8 - 8.1.1 Covers .
Page 236 8.8.5 Replacing the hoist rope ......... . . 8 - 60 8.8.6 Setting the lowering limit switch .
Page 237: Maintenance Work On The Superstructure
Maintenance work on the superstructure 8.1 General instructions Maintenance work on the superstructure General instructions 8.1.1 Covers Various types of work (e.g. oil change) require that covers be removed. Before maintenance work • Remove the covers (1) After maintenance work •...
Page 238: Overview Of Maintenance Work On The Superstructure
Maintenance work on the superstructure 8.1 General instructions 8.1.2 Overview of maintenance work on the superstructure 8 - 2 3 302 364 en Maintenance manual GMK 4100L-1...
Page 239 Maintenance work on the superstructure 8.1 General instructions à Symbols for maintenance work p. 8 - 7 à 1 CCS (Crane Control System) control unit p. 8 - 7 à Hoists p. 8 - 9 à 17 Hoist ropes p. 8 - 51 à...
Page 240 Maintenance work on the superstructure 8.1 General instructions 8 - 4 3 302 364 en Maintenance manual GMK 4100L-1...
Page 241 Maintenance work on the superstructure 8.1 General instructions à Main boom p. 8 - 45 à 1 Telescopic sections 1 to 6 and basic section p. 8 - 46 à 17 Derricking cylinder p. 8 - 45 à 16 Sheaves p.
Page 242 Maintenance work on the superstructure 8.1 General instructions Blank page 8 - 6 3 302 364 en Maintenance manual GMK 4100L-1...
Page 243: Symbols For Maintenance Work
Maintenance work on the superstructure 8.2 Symbols for maintenance work Symbols for maintenance work Check the following symbols every day before starting work. • Check the symbols on the CCS start menu ( Crane Control System ) in the crane cab each day before starting work. •...
Page 244 Maintenance work on the superstructure 8.2 Symbols for maintenance work Blank page 8 - 8 3 302 364 en Maintenance manual GMK 4100L-1...
Page 245: Hoists
Maintenance work on the superstructure 8.3 Hoists Hoists 8.3.1 Checking the oil level Spare parts Designation Quantity GROVE part no. and tools Oil inspection glass; complete 84012690 à Operating Prerequisites – The truck crane must be level and in on-road mode; Instructions .
Page 246: General Inspection
• Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or your repair crew. 8.3.3 Checking the hoist brake Check that the hoist brake is working correctly on the main hoist and the auxiliary hoist.
Page 247: Changing The Oil/Checking The Oil
Maintenance work on the superstructure 8.3 Hoists M 12 8.3.4 Changing the oil/checking the oil à • Comply also with the Run-in regulations , p. 4 - 1. Oil, spare parts, Gear oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502 classification 3.3 (0.9)
Page 248 Some abrasion particles may appear in the first oil filled. If you notice such particles during the first oil change (after 200 oper. hrs.), first consult before introducing any specific measures. Manitowoc Crane Care 8 - 12 3 302 364 en...
Page 249: Having A Partial Inspection Carried Out
Maintenance work on the superstructure 8.3 Hoists 8.3.5 Having a partial inspection carried out Only suitably trained specialists should carry out a partial inspection of – the multiple-disc brake, – the plug connections between the hydraulic motor and the multiple-disk brake, –...
Page 250 Maintenance work on the superstructure 8.3 Hoists Blank page 8 - 14 3 302 364 en Maintenance manual GMK 4100L-1...
Page 251: Slewing Gear
Maintenance work on the superstructure 8.4 Slewing gear Slewing gear 8.4.1 Checking the oil level Spare parts Designation Quantity GROVE part no. and tools Gasket 10 x 14 Cu DIN 7603 00117125 à Operating Prerequisites – The truck crane must be level and in on-road mode; Instructions .
Page 252: Checking For Leaks
• Check that pipes and hoses are tightly connected and undamaged. If any damage is found, report it to or an authorised Manitowoc Crane Care GROVE dealer or your repair crew. 8.4.3 Checking the slewing gear brake Prerequisites –...
Page 253 – If the superstructure does slew, the slewing gear brake is defective and must be repaired immediately by or an Manitowoc Crane Care authorised GROVE dealer. Maintenance manual 3 302 364 en 8 - 17...
Page 254 Maintenance work on the superstructure 8.4 Slewing gear • Switch the slewing gear off and switch the engine off. • Fasten the coil (1) to the valve Y 2307 using the nut (release the slewing gear brake). • Start the engine and check the slewing gear for correct operation.
Page 255: Changing The Oil/Checking The Oil
Maintenance work on the superstructure 8.4 Slewing gear M 12 8.4.4 Changing the oil/checking the oil à • Comply also with the Run-in regulations , p. 4 - 1. Oil, spare parts, Gear oil Designation Specification GROVE part no. tools in litres (gal) to DIN 51502 classification...
Page 256 Maintenance work on the superstructure 8.4 Slewing gear Draining oil • Remove the plate (1). • Place a container under the screws (2). • Unscrew the filter (4) and screws (3) and (2). • Drain the oil. • Replace the gasket and tighten the screws (2).
Page 257: Slewing Bearing
Maintenance work on the superstructure 8.5 Slewing bearing Slewing bearing 8.5.1 Checking the screws à • Run-in regulations , p. 4 - 1. Comply also with the Tools – Torque wrench. à – Auxiliary tools for the torque wrench; p. 8 - 23. Prerequisites –...
Page 258 Do not put the truck crane back into operation and have the slewing bearing repaired by Manitowoc Crane Care Access The outer ring is connected to the carrier with the screws (1).
Page 259 Maintenance work on the superstructure 8.5 Slewing bearing Selecting the tools Outer ring The screw heads (1) are easily accessible for fitting a socket wrench. Therefore, you can use manual or mechanical torque tools (electric or hydraulic drivers). Inner ring The screw head (1) is accessible only via the opening (2).
Page 260 Maintenance work on the superstructure 8.5 Slewing bearing • Checking the Divide the checking of the 72 screws into 18 working steps of 4 screws outer ring each (1). Between each of the 18 operation steps you need to rotate the turntable to the next group of 4 screws on the opposite side.
Page 261: Lubricating The Gear Teeth
Maintenance work on the superstructure 8.5 Slewing bearing 8.5.2 Lubricating the gear teeth Grease Designation Quantity GROVE part no. Adhesive lubricating grease 00554205 (spray can) Observe the instructions and safety instructions on the adhesive lubricating grease packaging. à Operating Instructions . Prerequisites –...
Page 262 Maintenance work on the superstructure 8.5 Slewing bearing First lubrication • Remove the plate (1). • Remove the old grease from all the gear teeth (2). • Apply a thin layer of new grease to all the gear teeth and allow it to penetrate for about 10 minutes.
Page 263: General Inspection
If unusual noises occur, take a sample of the grease that has escaped. Have examine the sample for metal residue. Manitowoc Crane Care • Check the slewing bearing for damage (e.g. gaskets). If any damage is found, report it to...
Page 264: Measuring Tilting Play
Maintenance work on the superstructure 8.5 Slewing bearing 8.5.4 Measuring tilting play • Reducing the When after several years of intensive crane operation, half of the value for interval the maximum permissible tilting play is reached, then you must reduce the maintenance interval.
Page 265 The base value of the tilting play is determined and documented by play or an authorised GROVE dealer when the slewing Manitowoc Crane Care bearing is put into operation or replaced. The maximum permissible wear is 3.2 mm (0.126 in).
Page 266: Lubricating The Locking Of Turntable
Maintenance work on the superstructure 8.5 Slewing bearing M 12 8.5.5 Lubricating the locking of turntable Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease to DIN 51502 classification Grease KP - 1K - 50 DIN 51825 03233369 –...
Page 267: Hydraulic System
Maintenance work on the superstructure 8.6 Hydraulic system Hydraulic system Risk of environmental damage due to leaking consumables. Always let consumables drain into suitable receptacles. Wipe up any consumables that escape. Store/dispose of consumables and any soaked equipment properly. Ask about the applicable regulations. 8.6.1 Checking the oil level à...
Page 268: Checking The Hydraulic Hoses
Maintenance work on the superstructure 8.6 Hydraulic system 8.6.2 Checking the hydraulic hoses The inspection work is described in section Checking the hydraulic hoses , p. 7 - 98. 8.6.3 Checking the ventilation filter • Check the display (1) on the ventilation filter. If the indicator is coloured à...
Page 269: Checking For Leaks
8 - 44. If damage cannot be rectified immediately or further damage is likely • Notify or an authorised GROVE dealer or your repair Manitowoc Crane Care crew. Maintenance manual 3 302 364 en 8 - 33 GMK 4100L-1...
Page 270: Cleaning The Magnetic Rods
Maintenance work on the superstructure 8.6 Hydraulic system 8.6.5 Cleaning the magnetic rods Spare parts Designation Quantity GROVE part no. and tools For oil filter 1: Filter 04156358 Packing set 04165792 à – Receptacle, approx. 5 ltr (1.5 gal); p. 2 - 4. Prerequisites –...
Page 271 Risk of damage to the hydraulic system. Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system inspected by or by Manitowoc Crane Care your qualified repair crew. • Assemble the filter (3) and insert it. •...
Page 272: Changing The Ventilation Filter
Maintenance work on the superstructure 8.6 Hydraulic system M 12 8.6.6 Changing the ventilation filter Spare parts Designation Quantity GROVE part no. and tools Filter 03134932 Prerequisites – The engine must be switched off and secured against unauthorised use; à p.
Page 273: Pressure Accumulator - Checking The Gas Pressure
180 bar (2610 psi) accumulator • Have the filling pressure checked and if necessary corrected by or an authorised Manitowoc Crane Care GROVE dealer. M 12 8.6.8 Taking oil samples The oil sample from the superstructure hydraulic system is taken in a way similar to that for the carrier hydraulic system.
Page 274 Maintenance work on the superstructure 8.6 Hydraulic system The MLS gauge port (1) is located on the bracket (2). When a hydraulic function is run (tilt the crane cab), oil can be taken at the gauge port. • This maintenance work must be performed by a team of two persons: –...
Page 275: Changing The Hydraulic Oil Filter
Maintenance work on the superstructure 8.6 Hydraulic system 8.6.9 Changing the hydraulic oil filter All oil filters must be replaced when changing the oil. If a warning message appears, the red symbols on the CCS control unit CCS indicate whether oil filter 1 or oil filter 2 is clogged. 1 red –...
Page 276 Large amounts of metal particles are a sign of damage in the hydraulic system. Have the hydraulic system checked by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew. • Assemble the filter (3) and insert it.
Page 277 Maintenance work on the superstructure 8.6 Hydraulic system Changing oil filter 2 • Release the receptacle (1) at the hexagon. • Change the filter (2). • Replace the gaskets. • Fill the receptacle with clean oil and tighten it – torque 25 Nm (18.5 lbf ft). After changing the filter Risk of damage to the hydraulic pumps...
Page 278: Changing The Hydraulic Oil
Maintenance work on the superstructure 8.6 Hydraulic system 8.6.10 Changing the hydraulic oil The oil only needs to be changed if the laboratory analysis results indicate à Taking oil samples , p. 8 - 37. this; Oil, spare parts, Hydraulic oil Designation Specification GROVE part no.
Page 279 Maintenance work on the superstructure 8.6 Hydraulic system Draining oil Risk of environmental damage due to leaking consumables. Use the supplied connecting piece and hose and a receptacle with sufficient capacity to drain the hydraulic oil. • Place a receptacle underneath the valve. •...
Page 280 Maintenance work on the superstructure 8.6 Hydraulic system Establishing the After having changed the oil filters and topping up the oil, you must operating re-establish the operating conditions. conditions Risk of damage to the hydraulic pumps Open the valve prior to starting the engine. This prevents damage to the hydraulic pumps.
Page 281: Main Boom
Maintenance work on the superstructure 8.7 Main boom Main boom 8.7.1 Greasing the piston rod of the derricking cylinder Grease, spare Designation GROVE part no. parts and tools Lubricant RHUS SW 2; 1 kg 03325215 (Apply the grease with a brush) Spray on Berulub;...
Page 282: Lubricating The Telescopic Sections
– A grease gun for the grease nipples on the upper telescopic slide faces. – A brush or roller for the outer, upper and lower telescopic slide faces. The Manitowoc Crane Group Germany GmbH recommends pneumatic grease spray guns for more effective lubrication of the telescopic slide...
Page 283 Maintenance work on the superstructure 8.7 Main boom If the desired telescoping status is not a fixed length, you can first telescope to the next closest fixed length with the semi-automation and then à Operating Instructions . telescope further to the desired length manually; Information Risk of overturning when telescoping if the RCL is overridden.
Page 284 Maintenance work on the superstructure 8.7 Main boom • Extend the telescopic section I to 50%. • Use the grease gun (PAL1) to lubricate the upper inner slide faces at the lubricating nipples (1) on both sides. • Fully retract telescopic section I . •...
Page 285 Maintenance work on the superstructure 8.7 Main boom • Derrick the main boom to 15°. • Retract the telescopic section V to 0% and extend the telescopic section VI to 50%. • Lower the main boom to 0° – do not lower to below 0°.
Page 286: Lubricating The Sheaves
Have damaged, worn, stiff or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care M 12 8.7.4 Checking the locking system Risk of accidents if maintenance work is not carried out.
Page 287: Hoist Ropes
Maintenance work on the superstructure 8.8 Hoist ropes Hoist ropes 8.8.1 Checking the winding Risk of accidents when the rope drum is turning. Keep away from the rope drum while it is turning. This will prevent your limbs from being drawn in and getting crushed. Prerequisites –...
Page 288: Checking The Hoist Ropes
Maintenance work on the superstructure 8.8 Hoist ropes 8.8.2 Checking the hoist ropes Spare parts – Torque wrench for 78 Nm (57.5 lbf ft). and tools – Establish a rigging mode in accordance with the Lifting capacity table Prerequisites à Operating Instructions .
Page 289: Lubricating The Hoist Rope
– by running it through a tray filled with lubricant or – by means of high-pressure lubrication with a pressure pump. The Manitowoc Crane Group Germany GmbH recommends high-pressure lubrication with a pressure pump (GROVE part no. 90018525) for reasons of sustainability, efficiency and environmental protection.
Page 290: Assessing The Condition Of The Hoist Rope
Maintenance work on the superstructure 8.8 Hoist ropes 8.8.4 Assessing the condition of the hoist rope If in doubt about damage assessment, always consult an official inspector. To assess the condition of the rope, you must be familiar with the following: –...
Page 291 Maintenance work on the superstructure 8.8 Hoist ropes The tables show by rope diameter the number of wire breaks in a length 6 times and 30 times the rope diameter which if reached would require replacement of the rope. • Familiarise yourself with DIN ISO 4309:2013-06 (rotation-resistant ropes).
Page 292 Maintenance work on the superstructure 8.8 Hoist ropes Risk of accidents due to reduced load bearing capacity. Remember that other factors may also make it necessary to replace a rope before the number of wire breaks requiring rope replacement has been reached (age of rope, frequency of use or exceptional loading).
Page 293 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Reduced The diameter of the Structural changes Replace the rope immediately diameter (1) rope has become if the diameter has decreased smaller along large by 15% or more compared to sections.
Page 294 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Loop forma- Outer layer wires General wear due to Immediately replace rope if the tion (1) in the form of hair ageing of the rope or rope structure has been pins are consequential substantially altered by the...
Page 295 Maintenance work on the superstructure 8.8 Hoist ropes Damage Description Cause Replacement Flattening (1) Crushed areas, Mechanical damage, Determine number of wire mostly with wire e. g. due to driving breaks; replace rope breaks. over the rope. immediately if serious crushing has occurred.
Page 296: Replacing The Hoist Rope
Maintenance work on the superstructure 8.8 Hoist ropes 8.8.5 Replacing the hoist rope à Spare parts – An authentic replacement rope; Rope certificate . and tools – A reel stand with braking block. – Torque wrench for 78 Nm (57.5 lbf ft). Risk of accidents from falling load.
Page 297 Maintenance work on the superstructure 8.8 Hoist ropes • Remove the clamp (4). • Push the rope through the bore (3) until the rope wedge (1) slides out of the pocket (2). • Remove the rope wedge and place the old rope away from the truck crane.
Page 298 Maintenance work on the superstructure 8.8 Hoist ropes • Guide the rope through the bore (3) until it protrudes about 1.5 m (5.0 ft) beyond the pocket (2). • Feed the free end of the rope back through the pocket. •...
Page 299: Setting The Lowering Limit Switch
Maintenance work on the superstructure 8.8 Hoist ropes Observe the hook block when unreeling. The hook block must not rotate. Risk of accidents if the lowering limit switch is set incorrectly. After inserting a new rope, the lowering limit switch must always be reset. In this way you avoid the lowering limit switch switching off too late or not at all, the rope being damaged and the load being dropped.
Page 300 Maintenance work on the superstructure 8.8 Hoist ropes Setting the lower- ing limit switch Risk of accidents if the rope end fitting is overloaded The lowering limit switch must always be reset after repair work on the hoist and after rope replacement. A faulty lowering limit switch must always be replaced.
Page 301: Cable Drums And Slewing Angle Sensor
Maintenance work on the superstructure 8.9 Cable drums and slewing angle sensor Cable drums and slewing angle sensor 8.9.1 Maintenance of the slip ring assemblies The slip ring assemblies are located in: 1 Cable drum 1 2 Cable drum 2 Spare parts and Designation Quantity...
Page 302 Maintenance work on the superstructure 8.9 Cable drums and slewing angle sensor Risk of damage to the RCL. Before maintenance work on the slip ring assemblies, always switch off the battery master switch so that the cable drum is without power. This prevents short circuits which may lead to damage to the rated capacity limiter (RCL).
Page 303: Lubricating The Slewing Angle Sensor
Maintenance work on the superstructure 8.9 Cable drums and slewing angle sensor 8.9.2 Lubricating the slewing angle sensor Grease, spare Lubricating Designation Specification GROVE part no. parts, tools grease to DIN 51502 classification Grease KP - 1K - 50 DIN 51825 03233369 Designation Quantity...
Page 304 Maintenance work on the superstructure 8.9 Cable drums and slewing angle sensor Blank page 8 - 68 3 302 364 en Maintenance manual GMK 4100L-1...
Page 305: Central Lubrication System
Maintenance work on the superstructure 8.10 Central lubrication system 8.10 Central lubrication system 8.10.1 Checking the level The maintenance of the pump (1) is similar to the maintenance on the carrier; à Central lubrication system , p. 7 - 115. Connected lubricating points –...
Page 306 Maintenance work on the superstructure 8.10 Central lubrication system Blank page 8 - 70 3 302 364 en Maintenance manual GMK 4100L-1...
Page 307: Hook Blocks
Check the sheaves in the hook blocks for damage, wear, mobility and extreme soiling. Have damaged, worn, stiff or extremely soiled sheaves replaced by or an authorised GROVE dealer or your repair crew. Manitowoc Crane Care M 12 8.11.2 Lubricating à...
Page 308 Some manufacturers recommend dismantling every 4 years or after 500 operating hours. • about the maintenance intervals for the hook Manitowoc Crane Care blocks supplied to you. • Have the hook blocks dismantled by or an Manitowoc Crane Care authorised GROVE dealer or your qualified repair crew.
Page 309: Electrical System
Checking the lighting and indicators Risk of accidents if the safety devices are faulty! Have faulty lights and indicators repaired by Manitowoc Crane Care an authorised GROVE dealer or an authorised specialist workshop. • Check the symbols and indicator lamps on the CCS (Crane Control System) à...
Page 310: Have The Battery On The Electronics Board Replaced
Maintenance work on the superstructure 8.12 Electrical system Risk of accidents from exploding glass bodies and high voltage. The glass bodies of gas discharge lamps (xenon lights) are pressurised. If the lamp breaks, the glass splinters explosively and shards scatter. Xenon lights operate at high voltage.
Page 311: Air Conditioning System
Maintenance work on the superstructure 8.13 Air conditioning system 8.13 Air conditioning system 8.13.1 Checking the air conditioning system • Check the air-conditioning system in the same way as when checking it on à Checking the air-conditioning system , p. 7 - 127. the carrier;...
Page 312: Checking Hoses
• Check all refrigerant hoses for damage and areas of wear. Have damaged hoses checked by or an authorised Manitowoc Crane Care GROVE dealer or an authorised specialist workshop only. M 12 8.13.4 Checking the entire air conditioning system...
Page 313 Maintenance work on the superstructure 8.13 Air conditioning system Refrigerant Fill quantity Designation CAS no. in kg (lbs) EC no. 1.0 (2.2) 1-circuit (3 KW) 811-97-2 Tetrafluoroethane (R134a) 212-377-0 2 x 0.95 (2.1) 2-circuit (6 KW) Compressor oil POE-OIL; EMKARATE RL68H Filler connections The filler connections (1) for the refrigerant are on the compressor behind the cover (2).
Page 314: Changing The Pollen Filter
Maintenance work on the superstructure 8.13 Air conditioning system M 12 8.13.5 Changing the pollen filter • Reducing the Under difficult operating conditions – at extremely sandy or dusty interval locations – you must change the filter earlier than normal. Spare parts Designation Quantity...
Page 315: Other Maintenance Work
Maintenance work on the superstructure 8.14 Other maintenance work 8.14 Other maintenance work 8.14.1 Checking the windscreen washing system Water, spare Designation Quantity GROVE part no. parts, tool Windscreen wiper blade 03268512 Roof wiper blade 03326121 – Water; add commercially available detergent and antifreeze to it. –...
Page 316: Checking The Auxiliary Heater
Maintenance work on the superstructure 8.14 Other maintenance work Wiping The wiping/washing system operation is described in the accompanying à Operating Instructions . operating instructions; • Spray water on the windscreen – press down on the switch. • Spray water on the skylight – press up on the switch. •...
Page 317: Lubricating The Crane Cab Door
Check if the door moves smoothly on the rails and if it locks easily. If the door is sluggish or does not close properly, have it reset by or an authorised GROVE-dealer. Manitowoc Crane Care Maintenance manual 3 302 364 en 8 - 81...
Page 318: Lubricating The Step
Fully retract the step. If the step is stiff, bent or does not retract completely, have the step aligned and adjusted by or an authorised GROVE dealer. Manitowoc Crane Care 8 - 82 3 302 364 en Maintenance manual GMK 4100L-1...
Page 319: Lubricating The Connecting And Socket Pins
Check the pins for wear such as rust, deformation, broken clips, chains and pin-type keepers. • If the pins are damaged, have them replaced by Manitowoc Crane Care or an authorised GROVE dealer or your qualified repair crew. • Use only authentic replacement pins.
Page 320: Renewing The Corrosion Protection
Maintenance work on the superstructure 8.14 Other maintenance work M 12 8.14.6 Renewing the corrosion protection Protective agent, Protective agent GROVE part no. tools Corrosion protection 03140192 – Spray gun with spray extension. – Brush. – Protective clothing, protective goggles. Prerequisites –...
Page 321 Maintenance work on the superstructure 8.14 Other maintenance work Spraying Risk of injury to the eyes. While working with the spray extension you could be hit by the spray jet or spray droplets. Wear protective goggles, protective clothing and gloves. •...
Page 322: Having The Fire Extinguisher Checked
Maintenance work on the superstructure 8.14 Other maintenance work 8.14.7 Having the fire extinguisher checked Depending on your truck crane's equipment, it can be fitted with fire extinguishers. The maintenance interval may even be shorter, depending on the respective national regulations and the operating location. Ask the local fire safety officer about the national and local regulations.
Page 323 Longer out of service periods Maintenance manual 3 302 364 en GMK 4100L-1...
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Page 325: Longer Out Of Service Periods
Longer out of service periods Longer out of service periods Carry out the following jobs if the truck crane is going to be out of service for a long period (months). • Putting the truck Clean the truck crane thoroughly on the inside and outside. crane out of •...
Page 326 Longer out of service periods • Ensure that the tyre positioning is different each time the crane is parked (without outriggers). • Seal the air filter again. If the truck crane is going to be out of service for more than 12 months: •...
Page 327 Torques 10.1 Torques for the retaining bolts ........10 - 10.2 Special torques .
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Page 329: Torques
Torques 10.1 Torques for the retaining bolts Torques 10.1 Torques for the retaining bolts Metric standard screw-thread Guide values Metric fine thread Thread size Torques (maximum permissible pre- (mm) tensioning for bolts) for oiled bolts (Nm) Size across flats (mm) Bolt quality Hexagon- Cylinder...
Page 330 Torques 10.2 Special torques 10.2 Special torques Thread size Size across flats Torque (Nm) (mm) (mm) Designation Hexagon- Cylinder head bolt screw Suspension strut: – Bracket for the vehicle M 16 — chassis, top – Bracket for the vehicle chassis, M 24 —...
Page 331 Spare parts required for maintenance 11.1 General information ..........11 - 11.2 Lighting .
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Page 333: Spare Parts Required For Maintenance
Spare parts required for maintenance 11.1 General information Spare parts required for maintenance 11.1 General information The spare parts required for maintenance are divided into – lighting, – spare parts for the carrier and – spare parts for the superstructure. The only spare parts listed here are those required for the maintenance work described.
Page 334 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number CARRIER LIGHTING: Front spotlights: (integrated in the bumper) – Daytime driving light (left) 04163680 – Daytime driving light (right) 04136679 – Low-beam + full-beam headlights 03134828 H7 24V –...
Page 335 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number White front marker lights: (at the top on the driver's cab) – Marker light 01207144 R10W 24V Outrigger beam spotlights: (above the front and rear outrigger beams) –...
Page 336 Spare parts required for maintenance 11.2 Lighting Installation point GROVE part Designation Power (W) number SUPERSTRUCTURE LIGHTING: Marker lights, yellow: (left and right on the main boom head) – Marker light; complete 03329569 Red rear marker lights: (on the turntable) –...
Page 337: Spare Parts For The Carrier
Spare parts required for maintenance 11.3 Spare parts for the carrier 11.3 Spare parts for the carrier Quantity, in single parts Assemblies and spare parts GROVE- For maintenance interval Carrier part number M 12 Engine Air filter – main filter 04158601 1 item when the symbol lights up Air filter –...
Page 338 Spare parts required for maintenance 11.3 Spare parts for the carrier Quantity, in single parts Assemblies and spare parts GROVE- For maintenance interval Carrier part number M 12 Wheels Wheel nuts for steel rims 01207756 In case of damage; 12 each per wheel Wheel nuts for aluminium rims 7659100000 Vehicle brake (for all 4 axle lines)
Page 339 Spare parts required for maintenance 11.3 Spare parts for the carrier Quantity, in single parts Assemblies and spare parts GROVE- For maintenance interval Carrier part number Y 10 Engine Oil filter with cover gasket 04163013 Original oil drain plug, complete 04161529 Transmission Filter...
Page 340: Spare Parts For The Superstructure
Spare parts required for maintenance 11.4 Spare parts for the superstructure 11.4 Spare parts for the superstructure Quantity, in single parts Assemblies and spare parts GROVE- For maintenance interval Superstructure part number M 12 Hoists Sight glass with hoses; complete 84012690 (if damaged) Slewing gear...
Page 341 Spare parts required for maintenance 11.4 Spare parts for the superstructure Assemblies and spare parts GROVE- Quantity, in single parts Superstructure part number For maintenance interval Y 10 Slewing angle sensor Gasket 16 x 20 Cu DIN 7603 00117134 Electrical system Lithium battery 3.6 V 03143172 Maintenance manual...
Page 342 Spare parts required for maintenance 11.4 Spare parts for the superstructure Blank page 11 - 10 3 302 364 en Maintenance manual GMK 4100L-1...
Page 343 Appendix Maintenance manual 3 302 364 en GMK 4100L-1...
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Page 345: Appendix
Appendix...

Manitowoc Grove GMK 4100L-1 Maintenance Manual

Table of Contents

2 2 Safety and Environmental Protection

6 6 Lubricants and Consumables

Lubricants

Lubricants and Consumables

Consumables

Refrigerant

7 7 Maintenance Work on the Carrier

General Instructions

Symbols for Maintenance Work

Engine

Fuel System

Exhaust System with Exhaust Emission Control

Transmission

Transfer Case

Angle Gear

Axle Lines

Wheels

Vehicle Brake

Suspension

Steering

Compressed Air System

Hydraulic System

Central Lubrication System

Electrical System

Air-Conditioning System

Towbar Coupling

Other Maintenance Work

8 8 Maintenance Work on the Superstructure

Maintenance Work on the Superstructure

General Instructions

Symbols for Maintenance Work

Hoists

Slewing Gear

Slewing Bearing

Hydraulic System

Main Boom

Hoist Ropes

Cable Drums and Slewing Angle Sensor

Central Lubrication System

Hook Blocks

Electrical System

Air Conditioning System

Other Maintenance Work

Appendix

Quick Links

Chapters

Need help?

Questions and answers

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Summary of Contents for Manitowoc Grove GMK 4100L-1